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Godless Commie's ungodly turbo project - R2S Progressive Twin Turbo
For the record, this is the build thread for the R2S Turbo system discussed in detail here:
Research stage discussions Here's what I intended to fit under the hood: https://cimg6.ibsrv.net/gimg/www.mia...96d54e6a13.jpg https://cimg7.ibsrv.net/gimg/www.mia...48fe0a3c16.jpg A progressive system made by BorgWarner, primarily intended for diesel applications. However, I soon found out that BW itself is actually looking into gasoline engine applications, and has even formed a department for R&D. That encouraged me, and I contacted the chief engineer in charge of that department. He was pretty interested in what I wanted to do, and helped me a great deal. This project, for the record, is a first of its kind. Meaning, no other idiot (other than yours truly) has even bothered to attempt utilizing this thing in a gasoline (or diesel) powered engine. To quickly recap my installation strategy, I had decided on the following:
So I started... |
Looking forward to what you come up with
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First order of business was figuring out the vacuum controls..
(I promised Joe I would post all the stupid mistakes I made, so I am not holding anything back here..) A little backstory: This system has a total of three vacuum controlled actuators:
That's the actuator on the far right in this pic (AKA "big boy") https://cimg7.ibsrv.net/gimg/www.mia...cf9476bf27.jpg
https://cimg5.ibsrv.net/gimg/www.mia...833e5c2129.jpg The small turbo (KP39) spools instantly and provides boost as low as 1000 RPM. All incoming air is fed through the larger turbo (K04), it spins and provides support for the HP turbo by means of compound boost until it takes over. The wastegate is funky.. It needs to be open below the 100 kPa level to provide fuel economy. I was told the HP turbo freewheels when the IWG is open and scavenges the exhaust, and that helps the engine efficiency a lot. |
Cool. This sounds interesting. Glad to see it start happening.
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Yuuuuuuusss
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I'm in for $5 toward the resulting dyno run.
Here is a Borg warner by the name of 7 of 9: |
I got some solenoids and started to look for a safe place to install them - no point in cooking stuff under the hood.
This area tucked in the left fender seemed like the best spot... https://cimg8.ibsrv.net/gimg/www.mia...7f652e0b9e.jpg Decorating the panel with solenoids.. (Never mind the MAC valve, I had to ultimately relocate it to an even cooler spot) https://cimg3.ibsrv.net/gimg/www.mia...89de74e472.jpg https://cimg2.ibsrv.net/gimg/www.mia...20ee394200.jpg https://cimg4.ibsrv.net/gimg/www.mia...db0d22650c.jpg https://cimg5.ibsrv.net/gimg/www.mia...eef91388f0.jpg |
I also made a manifold for vacuum distribution, using some aluminum stock..
https://cimg7.ibsrv.net/gimg/www.mia...8639855d1b.jpg https://cimg6.ibsrv.net/gimg/www.mia...975c1c79eb.jpg |
OK, this thing is vacuum controlled. That much is clear.
A turbo gasoline engine has no vacuum under boost. It has boost. Diesels are a different story, they have vacuum pumps, and do not care if they produce boost or not. I need vacuum, so I guess I will make myself a vacuum reservoir... Take two 20 Cm stainless steel Ikea salad bowls.. https://cimg5.ibsrv.net/gimg/www.mia...5b074102c7.jpg Drill 2 holes in one, install vacuum ports. https://cimg3.ibsrv.net/gimg/www.mia...2deff3dd14.jpg Gives you 4.2 liters of vacuum volume! https://cimg6.ibsrv.net/gimg/www.mia...2a4ad7c00b.jpg Attempt to weld them together, make a big mess, and run over to Iskender (grand master of welding and fabbing exquisite exhaust systems). Iskender welds it up while I enjoy my tea... Re-invent Sputnik in the process... https://cimg2.ibsrv.net/gimg/www.mia...cfb35e7c60.jpg Fits nicely under the left headlight, behind the bumper. https://cimg1.ibsrv.net/gimg/www.mia...67f3bced98.jpg https://cimg4.ibsrv.net/gimg/www.mia...52ffba6884.jpg |
Since I would be operating some pretty important stuff with vacuum while the engine was making boost, I began worrying about running out of vacuum.
I mean, what if I was on the gas for quite a while, like going uphill under boost for extended periods, operating actuators all the while, and using up all the vacuum? That's why I decided I should incorporate a vacuum pump in the system, and program its power source so that it would come on when vacuum was depleted to 60 kPa, and would cut off at 40 kPa. (I tested the actuators to see their minimum vacuum requirements) Here's that vacuum pump, testing the system before installation. It went just to to right of the left headlight, in front of the radiator, in a "cool" spot. Do not let the size fool you, damn thing draws vacuum down to 40 kPa pretty fast. https://cimg7.ibsrv.net/gimg/www.mia...2c47a3a365.jpg https://cimg8.ibsrv.net/gimg/www.mia...f2fe6b07ea.jpg That was good insurance. And then, I just wanted to see how many times my 4.2 liter vacuum reservoir would operate an actuator before it ran out of breath. Turns out, it had enough (with 30 kPa engine vacuum) to do 30 full strokes. That should be enough without any additional pump, but hey, the pump gives me a piece of mind. |
Speaking of using programmable MS outputs to control the solenoids, Dimitris told me I could use an NPN transistor to convert any unused IGN output to lowside.
A friend suggested I could use a VW/Audi ignition control module, and just hook up the outputs from MS to it. The module has very sturdy transistors in it, and I would get lowside outputs to run pretty much whatever I need within reason then. In other words, I would not have to worry about the load a solenoid would impart on the output. Neat. Here's the ignition control module: https://cimg9.ibsrv.net/gimg/www.mia...85443d1565.jpg I installed that module on the backside of the solenoid panel... https://cimg5.ibsrv.net/gimg/www.mia...584ace6644.jpg Which turned out to be a total failure... Turns out, while the transistors in the module does indeed convert a "+" signal to "-", it does that momentarily. Like firing an ignition coil. Just a trigger. I needed the damn thing to stay put, and be there as long as the conditions required a signal to be present. It was a noble idea, I just wrote it off to R&D expenses... |
So, instead of some ignition module, I decided I should use an NPN transistor like Dimitris suggested, but further isolate my MS from any load/mishap by utilizing an optocoupler, as well.
Half this project is paranoia, I swear. Here's what I did. I made an aluminum heat sink for the transistor, and secured the said transistor with a RIVET! (Gotta be a first) Configured the optocoupler for lowside, closed the lid, and I was done. The optocoupler draws 40 mAh. That's pretty much neglectable... https://cimg0.ibsrv.net/gimg/www.mia...33b41395d1.jpg You can clearly see the flyback diode on the lower left corner in this pic.. https://cimg1.ibsrv.net/gimg/www.mia...057f931bf1.jpg I liked it so much, I used optocouplers on all outputs. Better than a relay. https://cimg6.ibsrv.net/gimg/www.mia...8fa216b400.jpg I even used one on the warning lamp circuit of the alternator to trigger my electric power steering pump. (I have a custom 140 Amp alternator, and it has a conventional lamp circuit.) That way, the big pump comes on only when the alternator starts charging after the engine is running. https://cimg0.ibsrv.net/gimg/www.mia...38b1f73e25.jpg https://cimg1.ibsrv.net/gimg/www.mia...7e349cb98f.jpg |
I have read a ton of turbo build threads on this forum, and a lot of them either talk about heat management, or share horrible stories of heat damage.
An exhaust manifold is a major heat source. So is a turbocharger. And, there are 2 of them! İmages of melting master cylinders, hoses, my feet.. Pretty disturbing stuff. Guess what.. The bestest, most expensive insulation stuff on earth has air trapped in it. Air. What if I used air to deal with heat under the car then? The idea is simple: Make a second trans tunnel. Make it light. Make it a bit smaller than the actual tunnel itself, so you will have air between the the two. Allrighty then... Remove engine and transmission, take some 15 mm aluminum strips and knock out a smaller version of the tunnel, leaving about a 10 mm gap... https://cimg5.ibsrv.net/gimg/www.mia...09620bd4fd.jpg https://cimg9.ibsrv.net/gimg/www.mia...cf9bef9f3e.jpg https://cimg3.ibsrv.net/gimg/www.mia...8023a838d5.jpg Once you have the desired form, trim the excess strips, tie it all together. I used rivets for this job, makes life much easier. https://cimg8.ibsrv.net/gimg/www.mia...e9bdd00483.jpg https://cimg2.ibsrv.net/gimg/www.mia...b42e868e78.jpg https://cimg4.ibsrv.net/gimg/www.mia...4c8b9b6095.jpg |
Sir, you are nuts.
I love it. |
Removed the frame and started covering it.
I used 0.30 mm textured aluminum for that. Pretty lightweight stuff. https://cimg7.ibsrv.net/gimg/www.mia...395bc33b26.jpg https://cimg5.ibsrv.net/gimg/www.mia...48f6416447.jpg I riveted the aluminum sheet in sections, taking great care not to distort the frame. As careful as I was, there was a bit of distortion which gave some problems during the installation, but liberal use of harsh language came in pretty handy. https://cimg2.ibsrv.net/gimg/www.mia...0ad98a1c19.jpg https://cimg4.ibsrv.net/gimg/www.mia...90fa72b555.jpg https://cimg8.ibsrv.net/gimg/www.mia...513fc0b22f.jpg https://cimg6.ibsrv.net/gimg/www.mia...8d8469b8d3.jpg Nice and shiny, but not for long... |
I shot 2 layers of grey undercoating on the backside for further insulation and to prevent any buzz/rattling and associated shenanigans...
https://cimg2.ibsrv.net/gimg/www.mia...0aee32001f.jpg https://cimg3.ibsrv.net/gimg/www.mia...3a88f21287.jpg |
And, I used rivnuts to install the thing in the tunnel. Made my life easier.
Stainless M6 studs in the rivnuts, then stainless nuts.. (A total of 12 mounting points) https://cimg3.ibsrv.net/gimg/www.mia...509a5dab66.jpg https://cimg4.ibsrv.net/gimg/www.mia...64a7515b86.jpg |
This is the stuff I used.
I bought 2 1 meter by 2 meter sheets and used the rest on pretty much everywhere. https://cimg9.ibsrv.net/gimg/www.mia...73a1595bf3.jpg https://cimg3.ibsrv.net/gimg/www.mia...f0e4346a69.jpg |
I went ahead and undercoated the bottom of the car while I was at it.
Grey turned out to be an excellent choice. I can see everything while I am working under the car. And, leaving the trans side of the tunnel I installed uncoated gave me a great shiny surface. Working on the transmission is much easier now. It's not a black hole anymore. I have no pictures of the seemingly endless cleaning before I shot the undercoating. Hours of pressure washing and scrubbing, dirt, mud, road remnants running down my arms, crap all over the garage... Yeah, I wasn't thinking about taking pictures then. https://cimg0.ibsrv.net/gimg/www.mia...927e228cd4.jpg https://cimg3.ibsrv.net/gimg/www.mia...7e80e99b94.jpg |
This is what I waited for for four months...
There is one person I would trust with my project in all of Turkey, and he is an incredibly busy man. Iskender builds exotic exhaust systems for some very very high end cars, people bring brand new Lamborghinis, Ferraris, Porsches, Aston Martins, etc straight from the dealer for custom exhaust work. He is a cool guy, and I know him well. I went to him to see if he could build me the necessary components a couple days after I received this turbo system, and he told me to bring the car right away. Knowing his workload, I knew it would take a while. So, no complaints... (For the record, he charged me for materials only. What I paid him is nothing compared to what he charges his normal customers...) https://cimg4.ibsrv.net/gimg/www.mia...251dd4a500.jpg https://cimg5.ibsrv.net/gimg/www.mia...482bee3c08.jpg https://cimg6.ibsrv.net/gimg/www.mia...0333424ffa.jpg |
I brought the car back to the garage and removed everything...
You need to get creative when working alone... https://cimg7.ibsrv.net/gimg/www.mia...2bc07d3be4.jpg https://cimg6.ibsrv.net/gimg/www.mia...cb6371997a.jpg https://cimg8.ibsrv.net/gimg/www.mia...42c1af06a2.jpg Took the turbos apart (again) to really familiarize myself with its entrails... https://cimg4.ibsrv.net/gimg/www.mia...5873e3a3ea.jpg https://cimg1.ibsrv.net/gimg/www.mia...0d59a11bb5.jpg |
I wanted to get the oil return out of the way first.
AN fittings turned out to be cost prohibitive. (Turkish Lira took another swan dive against the Dollar.. Everything is expensive now with the 5.5 to 1 exchange rate) Anyway.. Considered plumbing fittings, but they proved to be too bulky... https://cimg4.ibsrv.net/gimg/www.mia...309babb86c.jpg So, I took a deep breath and went at it anyway. The hell with it, I said. I can get it patched up if I fcuk it up I said... https://cimg6.ibsrv.net/gimg/www.mia...fdd8e99f50.jpg I sourced some 19 (or 21?) mm ID aluminum pipe, cut it to size and had them welded. The hose is pretty flexible, is rated for elevated temps, and worked very well. https://cimg6.ibsrv.net/gimg/www.mia...7e0c351d02.jpg Both oil drain ports are within about 5 degrees of perpendicular. https://cimg7.ibsrv.net/gimg/www.mia...8652140523.jpg https://cimg8.ibsrv.net/gimg/www.mia...7a0fa6d6b8.jpg https://cimg1.ibsrv.net/gimg/www.mia...6c37153849.jpg I believe the ID is large enough to allow drainage... |
Since I had such a "cantilevered" setup, I did not want the weight of the turbo to yank the manifold studs out of the head, so I decided I should have an adjustable support system to take up the load.
https://cimg5.ibsrv.net/gimg/www.mia...4acced4319.jpg I used M10 stainless threaded rods with LH and RH threaded adapters so I could adjust the compression. https://cimg1.ibsrv.net/gimg/www.mia...87322da1aa.jpg Bolt holes in the block came in handy. https://cimg2.ibsrv.net/gimg/www.mia...64ca971978.jpg https://cimg3.ibsrv.net/gimg/www.mia...9ae9e0e245.jpg https://cimg4.ibsrv.net/gimg/www.mia...183b79fcd2.jpg I took the pics during mock up. Everything was cleaned up and painted before final assembly. There is one drawback to installing all this stuff here: I'll never be able to install AC on this car. Oh well. |
With the oil return all taken care of, it was time for oil feed lines.
Couple friends suggested I should route the lines around the back of the block, while some insisted they should be routed around the front. They all had their reasons, of course. I went with neither advice. My oil lines are routed THROUGH the engine. There is a "tunnel" right behind the timing belt rear cover, that's the tunnel I used. All I had to do was drill a couple holes on my sandwich plate, tap them for the custom hoses I had a hydraulic shop make for me, and the rest was easy... https://cimg4.ibsrv.net/gimg/www.mia...6a644afb3a.jpg Same hoses, with the alternator in place. https://cimg0.ibsrv.net/gimg/www.mia...e40158c7b8.jpg https://cimg1.ibsrv.net/gimg/www.mia...ccffd9c514.jpg The ends have banjo fittings and no restrictor. Turns out these turbos have their built in restrictors in their respective oil inlet ports. The chief engineer at BW confirmed this for me. https://cimg9.ibsrv.net/gimg/www.mia...a7c3f11883.jpg I used heat sleeves on every hose. These are rated for 1500 C - or so I'm told. They will be OK even if the manufacturer is exaggerating their rating by 50%. https://cimg0.ibsrv.net/gimg/www.mia...5f6a0d185d.jpg Oh, I also routed the coolant line for the wastegate this way, too. Going through the engine meant less clutter and using shorter hoses, but doing any kind of work under the intake manifold is a royal pain now. Removing the alternator requires a whole new procedure, for example... |
On a side note, I took a breather and replaced the rear deck carpeting @gesso brought for me all the way from California.
I really need to thank @Garman, @gesso and @sixshooter for their generosity, effort and all around camaraderie for this. My rear deck carpet had a big hole in it (it's an age thing, things wear out in time) and it looks pretty spiffy now. Did some surface rust removal and touch up paint while I was there... https://cimg9.ibsrv.net/gimg/www.mia...d36dc4a958.jpg To my horror, I discovered rust when I was removing the seats... So I tore them apart and had all the metal media blasted and powdercoated. I hate rust. https://cimg2.ibsrv.net/gimg/www.mia...60d3ac3e75.jpg https://cimg3.ibsrv.net/gimg/www.mia...b3b46114c0.jpg https://cimg4.ibsrv.net/gimg/www.mia...a03226cb66.jpg https://cimg5.ibsrv.net/gimg/www.mia...3fef633381.jpg https://cimg6.ibsrv.net/gimg/www.mia...7244efc8d4.jpg After media blasting and powdercoating... https://cimg9.ibsrv.net/gimg/www.mia...ced85fbc34.jpg https://cimg1.ibsrv.net/gimg/www.mia...5eaa7324b3.jpg https://cimg3.ibsrv.net/gimg/www.mia...ef8ea02967.jpg Wait.. This is supposed to be a turbo build thread. |
It has been 50 weeks since I started this project, and I have about 400+ pictures.
Sorting through all hat stuff takes a while. I have been sitting by he computer for several hours now, and I need to take a break... |
Where was I?
Oh, heat management/insulation stuff... I went nuts with it. Made heat shields to cover all exposed surfaces https://cimg3.ibsrv.net/gimg/www.mia...ba80ee8f8f.jpg Covered all the hoses with fiberglass insulation and wrapped them in aluminum tape... https://cimg8.ibsrv.net/gimg/www.mia...7d8c319dc8.jpg And fabbed a heat shield to protect master cylinders and stuff. That shield has ceramic wool sandwiched between 1 mm aluminum sheet and that .30 mm textured stuff I really like using. Unfortunately, I had to junk it. Did not work. I made quite a few pieces like this one, they all ended up in the trash... https://cimg3.ibsrv.net/gimg/www.mia...dcbb69b20d.jpg |
I had this great idea...
I would encapsulate the turbos and the manifold in an insulated heat shield. There is an opening between the bottom of the radiator and the belly pan. It is roughly 25" x 2". I would make a scoop there to collect the air rushing under the radiator, route it up and blow it into the heat shield encapsulating the turbos. The hot air would then be diverted into the (now well insulated) trans tunnel and away from the car. The idea seemed very cool, so I started on it... https://cimg3.ibsrv.net/gimg/www.mia...c1bf7c2de9.jpg https://cimg4.ibsrv.net/gimg/www.mia...a88f405433.jpg I roughed it out using cardboard... |
A foam core mock up was next..
https://cimg7.ibsrv.net/gimg/www.mia...a9a8cbc0af.jpg https://cimg0.ibsrv.net/gimg/www.mia...ec35744130.jpg ... followed by aluminum sheet. https://cimg3.ibsrv.net/gimg/www.mia...606798f61b.jpg https://cimg4.ibsrv.net/gimg/www.mia...18062fbf82.jpg This would be a three layer shield, too. Two layers of .30 mm aluminum, with ceramic wool in between. Ceramic wool is an amazing insulator, btw. https://cimg5.ibsrv.net/gimg/www.mia...21ad06838e.jpg https://cimg6.ibsrv.net/gimg/www.mia...c6899f094d.jpg |
Attachment point for the heat shield.
It would have welded studs pointing up to secure the heat shield. https://cimg3.ibsrv.net/gimg/www.mia...0ce9f8d75a.jpg https://cimg4.ibsrv.net/gimg/www.mia...9f58d99965.jpg https://cimg5.ibsrv.net/gimg/www.mia...fe7ad45740.jpg https://cimg7.ibsrv.net/gimg/www.mia...80727da5ef.jpg https://cimg9.ibsrv.net/gimg/www.mia...eee80a7811.jpg https://cimg2.ibsrv.net/gimg/www.mia...4c0887e291.jpg I was just about to install the whole thing when I had an epiphany and changed my mind. That setup went to the trash, as well. |
I decided covering up the heat source wold ultimately trap the heat, and went another direction...
I would cut the hood and make an active vent system! Because this project was nowhere near complicated enough! Because I was facing a credible risk of finishing the damn project before the year's end if I had stuck with my original plan! Because I somehow found pleasure in making things more challenging for no apparent reason. So I happily proceeded to design an active system. I mean, what's wrong with just a fixed louver vent? Nooo, gotta be active. Jeez. ***** That thing went through several design stages, several incarnations, several prototypes. Many camels were smoked, many pots of tea was consumed in the process... This was the first draft outline... https://cimg2.ibsrv.net/gimg/www.mia...8b7c437a35.jpg https://cimg1.ibsrv.net/gimg/www.mia...0cc81613eb.jpg Next step would be a plaster mold of the hood, because it has curves. A flat vent frame would distort the hood and ruin he car, so here we go... (The entire hood as well as fenders are covered in thick, clear plastic film at this point.) https://cimg3.ibsrv.net/gimg/www.mia...9bd824dc89.jpg https://cimg2.ibsrv.net/gimg/www.mia...a591a9dceb.jpg https://cimg1.ibsrv.net/gimg/www.mia...7c0edee344.jpg The mold gave me all the curves of the hood, and I proceeded to make a foam core prototype accordingly. https://cimg4.ibsrv.net/gimg/www.mia...7ec37129d1.jpg This frame would not distort the hood, that's for sure... https://cimg8.ibsrv.net/gimg/www.mia...bae4d5e9bd.jpg https://cimg0.ibsrv.net/gimg/www.mia...75c30c577c.jpg Turned out it was pretty impractical for an active setup, because the louvers would never be parallel to each other. I mean, I had selected the shape and the location meticulously, pouring over pressure maps, forum posts, youtube videos and whathaveyou... Time to start all over. |
Bananas
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Subscribed to the most epic build ever.
I have never heard of an optocoupler. Looks like the relay stuffs I've been using for arduino things. Maybe the chinese call it a relay so people like me know it's function. How do you retighten the nuts inside Sputnik when they get loose? Or did you just tighten them a lot and loctite them? |
Originally Posted by TurboTim
(Post 1515660)
Subscribed to the most epic build ever.
I have never heard of an optocoupler. Looks like the relay stuffs I've been using for arduino things. Maybe the chinese call it a relay so people like me know it's function. How do you retighten the nuts inside Sputnik when they get loose? Or did you just tighten them a lot and loctite them? An optocoupler is a common electronic component used to isolate a signal from the input side to the output side. It allows you to control stuff without actually connecting to it electrically. |
The more I read the more my mouth hung open. You spent too much time on that junkyard wars TV show. Your idea of normal construction is obviously skewed now, lol.
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Originally Posted by sixshooter
(Post 1515687)
The more I read the more my mouth hung open. You spent too much time on that junkyard wars TV show. Your idea of normal construction is obviously skewed now, lol.
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Kept trying different designs, attachment styles, shapes...
https://cimg0.ibsrv.net/gimg/www.mia...f56b3e628a.jpg https://cimg2.ibsrv.net/gimg/www.mia...ea66ae3faf.jpg https://cimg5.ibsrv.net/gimg/www.mia...8d62a0627f.jpg https://cimg8.ibsrv.net/gimg/www.mia...3d6bb05b9c.jpg https://cimg1.ibsrv.net/gimg/www.mia...ac09a07150.jpg https://cimg3.ibsrv.net/gimg/www.mia...7fe909ad08.jpg Chucked them all. The only cost was time at this point, and I had time. A couple friends - industrial designers by trade - volunteered to help me at that point. We fired up some 3D programs and went at it full speed... |
More plaster molds of the hood...
https://cimg4.ibsrv.net/gimg/www.mia...c0576ff147.jpg https://cimg9.ibsrv.net/gimg/www.mia...a26f4594e5.jpg This one proved to be very useful, and I used it as my master mold... |
I had thought of a trick for this mold..
It would give me a raised area for the area to be cut on the hood, so I could "wrap" the frame around it to give it the proper curvatures. This one worked. https://cimg5.ibsrv.net/gimg/www.mia...cc7597a354.jpg Had another prototype cut out of cardboard. I was planning on using 1.5 mm steel for the whole thing, so we had this cut from 1.5 mm cardboard. The result was very satisfactory. https://cimg3.ibsrv.net/gimg/www.mia...9d9fb2ffbd.jpg Please note the first slat, it sits at 90 degrees, while the others are at 45. The reason behind this configuration is allowing the air to tumble over the upright slat, creating more of a low pressure zone over the rest of the louvers. Science. https://cimg4.ibsrv.net/gimg/www.mia...96200072f8.jpg And they all close flat 3 minutes after I turn off the engine, once most of the heat rises away. I have already built an override switch inside the center console. That way, the louvers will not get stuck and bind if there is ice or snow on the hood. I can turn it off if I have to. https://cimg6.ibsrv.net/gimg/www.mia...c57b610e78.jpg https://cimg8.ibsrv.net/gimg/www.mia...109d14308d.jpg https://cimg2.ibsrv.net/gimg/www.mia...47e01ef280.jpg https://cimg3.ibsrv.net/gimg/www.mia...bfffb30fa6.jpg https://cimg4.ibsrv.net/gimg/www.mia...c05327fcf3.jpg https://cimg5.ibsrv.net/gimg/www.mia...d844a61254.jpg Feeling content with the result, it was time to fab the thing out of metal. We decided it should be body color for a number of reasons: Attracting less attention was a factor, but aesthetics was the ultimate motivation in that decision. |
With the air exit all figured out, I turned my attention to the air entering the engine bay.
I had installed a bunch of air diverters that channeled the incoming air through the radiator a few years ago, but they were ABS plastic, and had all turned pretty janky over time. Some were cracked, a couple were broken all the way. I thought nothing would be better than polycarbonate, and used a 2.3 mm sheet to replicate and replace them. https://cimg7.ibsrv.net/gimg/www.mia...10ed029457.jpg https://cimg6.ibsrv.net/gimg/www.mia...6eb58b4dba.jpg https://cimg5.ibsrv.net/gimg/www.mia...ae5d246a4f.jpg Also, there was a 2" opening between the radiator and the aluminum flat belly pan I had made about a year ago. Now that I had discarded the idea of fabbing a scoop there, I decided I should make another diverter (fixed on the belly pan) to direct all the air to the radiator. Took some measurements.. https://cimg7.ibsrv.net/gimg/www.mia...ffb4b6ce7d.jpg https://cimg5.ibsrv.net/gimg/www.mia...8226851160.jpg And bent it out of 1.5 mm aluminum. A rubber mallet produces excellent results, and I can get the angles just right. (I do not have room for a metal brake, and I don't bend stuff often, so this method works for me) https://cimg8.ibsrv.net/gimg/www.mia...534f287fce.jpg https://cimg6.ibsrv.net/gimg/www.mia...48e2818409.jpg I used rivets to install it on the belly pan, works like a charm. It can be (barely) seen below the radiator in this photo: https://cimg6.ibsrv.net/gimg/www.mia...953160ecb4.jpg |
All that work made me pretty hungry, too.
Late night snack... https://cimg5.ibsrv.net/gimg/www.mia...099c3e6f2b.jpg |
I needed all the room I could create to fit everything, and I had trouble routing the intake piping from the air cleaner to the turbo.
Plus, the recirculating BOV would have to be plumbed into that piping, as well. The solution was not simple. I had the radiator re-cored. (It had a couple leaks, anyway) It had a 32 Cm core, new core is 30 Cm tall. 2 Cm difference meant a lot. https://cimg7.ibsrv.net/gimg/www.mia...a1ee0e8af6.jpg The fans still fit perfectly. |
The now shorter radiator presented a problem:
The upper radiator shield no longer fit properly. I just had to make a new one. A dead battery makes an excellent dead weight while cutting metal. My tool may not be shielded, but I wear goggles (and a face shield if I am not smoking at the time) https://cimg2.ibsrv.net/gimg/www.mia...518f734b83.jpg I may or may not paint it black, haven't decided yet. https://cimg1.ibsrv.net/gimg/www.mia...64f461d1d0.jpg https://cimg3.ibsrv.net/gimg/www.mia...3ca9f06b2c.jpg https://cimg4.ibsrv.net/gimg/www.mia...a4fec6ed3d.jpg |
Meanwhile, the fact that the wastegate was sitting too close to the turbine housing made me pretty uncomfortable.
I know it is a "hot" component, but there's no point in cooking the thing.. https://cimg5.ibsrv.net/gimg/www.mia...46ec06a5df.jpg https://cimg6.ibsrv.net/gimg/www.mia...b32ff9a71e.jpg https://cimg3.ibsrv.net/gimg/www.mia...2a40f14810.jpg I made a nice insulated heat shield for it, and then plumbed cooling lines per @TurboTim's suggestion. You can barely see the heat shield under the WG in this photo.. https://cimg2.ibsrv.net/gimg/www.mia...8246a9c224.jpg |
Took the car out, cleaned and washed the vacant engine bay before I repainted all the scratched surfaces.
All that trial fit, installing and removing the turbo, DP and whatnot took its toll in there. https://cimg2.ibsrv.net/gimg/www.mia...9d2116bffd.jpg Edit: I found an after photo: https://cimg8.ibsrv.net/gimg/www.mia...6670933aa1.jpg |
Looks exactly like mine (color, ABS, etc). Is that an MSM? What is the large tube looking thing on the bottom left of the photo?
|
More on heat management...
The downpipe runs pretty close to the gearbox. I wanted to protect that from the heat, too, so I came up with this: https://cimg8.ibsrv.net/gimg/www.mia...b5bc2c161c.jpg https://cimg3.ibsrv.net/gimg/www.mia...9c53285a62.jpg https://cimg6.ibsrv.net/gimg/www.mia...80d7eb0141.jpg https://cimg7.ibsrv.net/gimg/www.mia...f28533a9ff.jpg https://cimg9.ibsrv.net/gimg/www.mia...bf77caf842.jpg I used this really cool, closed cell insulation stuff I had in the garage. It's a peel and stick type sheet insulation that can take some pretty high temps. Using 0.30 mm aluminum on the sticky side gave me extra weather protection, and a really shiny surface to reflect heat. I riveted some straps, cut a couple of large clamps, and wrapped it around the gearbox. Worked like a charm |
Originally Posted by Mudflap
(Post 1515721)
Looks exactly like mine (color, ABS, etc). Is that an MSM? What is the large tube looking thing on the bottom left of the photo?
I guess option packages on this side of the planet are different. As for the large tube looking thing, it is my electric PS pump. Details here... |
It was time to install the engine and gearbox back in the car to finish all the electrical work...
https://cimg2.ibsrv.net/gimg/www.mia...ff057f4547.jpg I wanted to see the engine running for the first time with the turbos. https://cimg4.ibsrv.net/gimg/www.mia...afa660e850.jpg |
Well, this happened...
You can hear it clearly here: And, this turned out to be the culprit. Damn. |
Damn...
I removed the engine, tore it apart, and ran to the machine shop with it. https://cimg3.ibsrv.net/gimg/www.mia...2495452e4e.jpg https://cimg5.ibsrv.net/gimg/www.mia...2e1e637754.jpg Turns out, it was a minor blessing in disguise. We discovered scratches on the crank and decided to machine it. Which meant sourcing .25 over bearings with short notice, among other parts. https://cimg6.ibsrv.net/gimg/www.mia...7ceacf5e82.jpg Here are the offending wrist pin bushings.. https://cimg7.ibsrv.net/gimg/www.mia...eaf2a1bbe6.jpg https://cimg7.ibsrv.net/gimg/www.mia...2df11ae927.jpg And the crank, waiting to be machined... https://cimg4.ibsrv.net/gimg/www.mia...d1a38efa01.jpg I was pretty lucky. The machine shop had the proper bushings on hand. I was able to find OEM bearings locally. Looked like we would not be able to find rings, and a custom fabricator agreed to make them. The catch was, their rings would be 1.2 mm thick. Je pistons use 1.00 mm rings. I called JE, they told me it would not be a problem at all to enlarge the ring grooves by 0.2 mm. Placed the order, and custom rings were made. I got the necessary gaskets and stuff from Mazda, they gave me an excellent deal... |
Well, turns out they gave me the wrong pan gasket...
This is what happened as soon as I was done torquing the pan bolts: https://cimg3.ibsrv.net/gimg/www.mia...93446f5180.jpg https://cimg7.ibsrv.net/gimg/www.mia...a153c1e33d.jpg To be fair, they were very understanding. Parts manager apologized and exchanged that now mangled gasket with a new one. Rest of the engine build went pretty uneventful. Somber, but uneventful nonetheless. |
I had a metric ton of electrical work to do while the engine was at the machine shop..
All the new solenoids had to be wired in, all defunct wiring had to be cleaned up. Yes, ECU location is under the passenger floor mat in European NBs. Frankly, I had an embarrassing mess down there. I had installed and removed countless pieces of gizmos over the years, and never seemed to have the time to properly remove their associated wiring when I uninstalled them. I had bundles of wires going nowhere... https://cimg7.ibsrv.net/gimg/www.mia...d74bbd575.jpeg https://cimg8.ibsrv.net/gimg/www.mia...d25328404f.jpg Working methodically, I did a thorough cleaning, installed new wiring, and took detailed notes this time. I also bought about 10 pairs of various weatherproof plugs with pigtails, and made all additions/extensions to the ECU much easier to deal with. https://cimg3.ibsrv.net/gimg/www.mia...2022a49f47.jpg https://cimg5.ibsrv.net/gimg/www.mia...534817513d.jpg https://cimg6.ibsrv.net/gimg/www.mia...6840b2176e.jpg This is about a week's work. Not pictured is a massive bundle of wire, sheathing and funky connectors which just acted as ballast in the car. https://cimg2.ibsrv.net/gimg/www.mia...5e266a62d3.jpg Yeah, I get hungry... https://cimg0.ibsrv.net/gimg/www.mia...8ca27b837b.jpg |
Proceeded to make a new cold air chamber for the air filter.
Had this brilliant idea to install my EBC solenoid, relay for the vacuum pump, and the second MAP sensor in there, too. (more on that "second MAP sensor" later) https://cimg8.ibsrv.net/gimg/www.mia...033f040540.jpg https://cimg0.ibsrv.net/gimg/www.mia...39baec0e4d.jpg This one is insulated with ceramic wool, too. |
Inner tie rod boots needed some TLC...
https://cimg7.ibsrv.net/gimg/www.mia...3579a8c772.jpg https://cimg9.ibsrv.net/gimg/www.mia...3fca1bc4eb.jpg https://cimg8.ibsrv.net/gimg/www.mia...215a5201c2.jpg |
Yes, definitely want to put EBC solenoid in the cold air box. Some day I'll get around to building one. I like the way you enclosed the top of yours. It's not like the filter needs servicing a lot.
Jelly that you don't have to fight the ECU located between brake and clutch like USA. |
Again, on an unrelated note, this is how I do maintenance on the water injection nozzles...
I remove them maybe two - three times a year, and give them a good ultrasonic cleaning. This ensures clog free operation. I had a nozzle clog on me in the past, and the car acts very funny because a clogged nozzle just drips and causes very strange low rpm / tip in hesitation. It was a good time to clean them before the engine went in the car. https://cimg5.ibsrv.net/gimg/www.mia...dba7db0fab.jpg https://cimg6.ibsrv.net/gimg/www.mia...f7ee7965c8.jpg https://cimg4.ibsrv.net/gimg/www.mia...1d770c02eb.jpg |
Originally Posted by TurboTim
(Post 1515660)
Subscribed to the most epic build ever.
I have never heard of an optocoupler. Looks like the relay stuffs I've been using for arduino things. Maybe the chinese call it a relay so people like me know it's function. How do you retighten the nuts inside Sputnik when they get loose? Or did you just tighten them a lot and loctite them? The relay could be fed by a third circuit to make this scenario even more ridiculous.. As for the nipples on the canister, they have 1/8 NPT thread. I have never had conical threads go loose on me before. You tighten them, and they stay that way. Oh, I made sure they were TIGHT. |
Even though I was going to have a large hood vent right above the hot parts, I still wanted to protect the master cylinders and electrical parts.
I have all my control solenoids, and the stepper motor for my active suspension system there. A heat shield needed to be designed and made, but there was an unexpected obstacle... https://cimg7.ibsrv.net/gimg/www.mia...0ebb367b58.jpg See that brake line coming from the master cylinder? Damn thing was protruding too much. (The photo is misleading, because I was not right above the brake line when I took it.) It was occupying the same plane with the wastegate to DP connection. https://cimg1.ibsrv.net/gimg/www.mia...222293cb7f.jpg I removed the brake line, put in a piece of sturdy copper wire to figure out the best shape and minimum bends that would give me enough room. https://cimg7.ibsrv.net/gimg/www.mia...57027d384b.jpg No dice... There was no way a brake line could be bent that close to the nut. I said the hell with it, and had a flexible line made with banjo fittings. I mean, brake fluid is dumb. It can't tell a flexible line from a steel pipe, right? Look carefully, you can see it coming out of the front of the MC. https://cimg1.ibsrv.net/gimg/www.mia...a34f53f860.jpg I win. period. https://cimg0.ibsrv.net/gimg/www.mia...bf83d7da78.jpg There's even an anti-rattle device on the heat shield. Or, I just stuck a piece of insulation on the aluminum to keep it from buzzing. |
Let's pause for a moment to admire the glorious engine mounts I made...
Shore 57A polyurethane bushings, hand cast by yours truly. Painted red, because why not... Grade 12.9 hardware, because I am paranoid. https://cimg0.ibsrv.net/gimg/www.mia...ab3f46cf99.jpg https://cimg1.ibsrv.net/gimg/www.mia...360f73875e.jpg |
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