4k-c Turbo Build!

[madrolla68]

Think the falcon's are 36/3. From memory.

 

And diesel turbo. They are designed for all low end. And can normally handle alot of boost. If you already have it and it's brand new then use it. Alot of people suggest and like turbo's with 0.48 rear. So it's only a touch smaller. Little bit earlier spool. So shouldn't be to bad. See if you can find out the wheel sizes. And taz_rx or madrolla68 will know better then me

 

Turbo charger aren't fuel specific,it all depends on how it is matched to the engine.

 

On mine i actually ran a turbo that came from a 2.0 SAAB diesel.

[Taz_Rx]

A/R's aren't everything. :( The actual size and flow of the turbo are more important. If the turbo is too big (or too small - like a CT9 :lol: ) then no amount of A/R adjustment will correct it effectively.

We need a bit more info on the turbo Mitch, or maybe a pic? Also remember that deisel turbos are only really designed to flow up to 2000-5000rpm.

 

 

You heard anything more about whats happening with your old car Matt? Is the guy who bought it re-shelling the turbo motor?

Edited June 16, 2010 by Taz_Rx

[ca18 bluebird]

suck through and water meth injection easiest way.

[madrolla68]

A/R's aren't everything. :jamie: The actual size and flow of the turbo are more important. If the turbo is too big (or too small - like a CT9 :jamie: ) then no amount of A/R adjustment will correct it effectively.

We need a bit more info on the turbo Mitch, or maybe a pic? Also remember that deisel turbos are only really designed to flow up to 2000-5000rpm.

 

 

You heard anything more about whats happening with your old car Matt? Is the guy who bought it re-shelling the turbo motor?

 

Thats what the pan was ,he used to ring me every other day but haven't heard boo for months. I don't think he actually knew what he was buying once he saw the car and exactly how much stuff was in it. He wasn't really that mechanically/electrically minded.

 

MMMMMMMMM

[Taz_Rx]

So we might see everything up for sale again when he gives up!? :jamie:

[Jaydnisevil]

So we might see everything up for sale again when he gives up!? :jamie:

 

 

Actually its coming together quite nicely :)

Its not a daily drive so my motivation has been fairly low, but I will say I'm kinda excited to Finnish it up now :)

Custom work has been the hard part, and getting the parts. Most of it done rather cheaply :)

 

Whats been done:

Well I can't remember what I had said I was up to (If anything) so current list of completions and to-do

 

Completed:

* Weight reduction - Nearly everything is stripped out, one drivers seat and dash frame remain (with cluster) :)

* Boost gauge - mounted neatly where the clock used to sit :)

* Exhaust manifold - Knocked out the heater port, blocked up the old exit, made an adapter plate from 3 - 4 bolt holes held with unbrakos :)

* Coolant supply lines - No heater box anymore, so pinched the supply lines from there :P

* Oil supply - Used a T- peice from the sensor

* Oil returne - 90% done, just need to cut a hole in the sump.

* Manifold - 80% complete, Custom manifold plates cut from steel, log manifold complete (Need to cut hole for supply tube and seal up ends with welsh plugs and tac in place)

* Missile switch's - Un- necessary but just for novelty really :P

 

To-do:

* Finnish manifold

* cut hole in sump

* new radiator thermo fan

* Throttle cable needs replacment (too short)

* weld up the rear diff ;) :P

* Ohh waste gate lever needs to be re attached (hits manifold :( )

 

In terms of running, its just the manifold completion needed :)

Driving may be a few weeks away yet :P

 

Photos:

Boost gauge mounting ;): http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_1181.jpg

Origional issue with the plates: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_0845.jpg

Lol missile switches + starter: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_0840.jpg

Exhaust adapter plate: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_0578.jpg

Manifold plates cut by hand: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_0666.jpg

Manifold being welded by a guy from work: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_1907.jpg

Completed manifold (minus end caps): http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_1909.jpg

Manifold on engine: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_1916.jpg

Plan for supply pipe: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_1919.jpg

Oil supply adapter: http://i201.photobucket.com/albums/aa93/jaydnisevil/IMG_1882.jpg

Edited March 31, 2011 by Jaydnisevil

[ae824ate]

Great to see you are getting there slowly. Better than rushing and giving up half way through.

[Jaydnisevil]

http://s201.photobucket.com/albums/aa93/jaydnisevil/?action=view&current=IMG_2027.mp4

 

Haha timing issue rectified, its now running :D

Its still just dummied together, but it runs :) Proof of concept and setup :)

 

http://s201.photobucket.com/albums/aa93/jaydnisevil/?action=view&current=IMG_2029.mp4

http://s201.photobucket.com/albums/aa93/jaydnisevil/?action=view&current=IMG_2031.mp4

 

Tomorrow ill be drilling the sump for the oil return (at that point was draining in to a tub :P )

Ill shorten the oil hoses to the lengths I need and am happy with, put clamps on everything, get some proper pipe for the fuel supply hose and rout that :)

 

Iv solved my waste-gate dilemma (well theoretically) So I'm going to work on phase 1 of that, and kick off phase two when I have some more money :)

I'm pretty excited actually :D

The fuel mixture and timing needs to be sorted out, but it runs for now :D

 

Question though, does it sound like its running on 3 cylinders to anybody else?

Maybe its just because its coming straight out the back of the turbo it sounds a bit funky.

Ill have to do some checks tomorrow, see if its just a spark issue :)

Could also be because I'm not using a gasket, just sealant. Would explain why it was a bit reluctant to rev up (Relative to my throttle position)

Also, I am in need of a new gasket for my manifold!! PLEASE let me know where I can get one?

I'm thinking autobarn or repco, the intnernets has a few but can't find anything in aus :(

That or I'm too tired and am going blind :P

 

*Edit, stumbled accross one on ebay. Google found it, the ebay search turned up squat lol*

Edited April 16, 2011 by Jaydnisevil

[Twinky]

Sprint auto parts can supply any gasket you want for the 4k.

[Jaydnisevil]

Timing Issue fixed, turns out the firing order was out somehow :S

Suppose thats what happens when you start a project over a year ago and forget how things went back on :P

 

Anywho I has a gasket in place now, all bolts are in place, only one last thing left to make a gasket for the turbo outlet (Cold side)

 

http://youtu.be/xKmtsJYdWSs

 

Ok opinion time peoples!

 

Wastegate plan 1:

The Arm currently hits my runner, and I need to cut it off, re-position and weld. Then make a bracket for the actuator, and make the back plate for the outlet of the turbo, somehow allowing for the wastegate to open enough.

 

Wastegate plan 2:

 

Bracket the stock one shut

On the old exhaust outlet (which is currently blocked up with a plate) I wanted to mount an external gate.

Ill still have to make the plate for the back of the turbo, but wont have to allow for that stupid plate to move around :)

Edited April 17, 2011 by Jaydnisevil

[Mitch-12]

hey mate what size are your intake runners on your custom intake plenum?

[20vT]

Really starting to come along mate, but please tell me that you are going to be changing the Silicone intake so something a little less....flexible, but its looking good

[Jaydnisevil]

hey mate what size are your intake runners on your custom intake plenum?

 

The runners are 1 1/4", the inlet to the log is 1.5" and the 'plenum' lol its just a piece of 2.5" pipe)

I do plan on cutting off the end plates and replacing with something a little less 'gheto' later down the line (Maybe welsh plugs)

But I needed to check it all worked, so this is V1.0 if you wish :P

 

Really starting to come along mate, but please tell me that you are going to be changing the Silicone intake so something a little less....flexible, but its looking good

 

Haha possibly, but I will be re-enforcing it with an internal spring to prevent that collapse :)

If it does not solve my problem, I will be getting a reinforced joiner. I wanted a flexi joiner because it allows for expansion and vibration, but I will not be leaving the joiner in its current state :P

Thanks :) can't wait to get it on the road, but baby steps. I'm excited but in no rush to get it going, I'm still gonna try and do it properly :)

[Jaydnisevil]

Ok, got some oil in the dashpot and a spring now in the silicone joiner :)

I bought a lower radiator hose and pulled the spring out of that, worked perfectly :)

 

I still need to drill the sump, its the only thing stopping me from running the engine longer. Not a huge task :)

The radiator has a leak where snapped the 'shroud' off :P So will oxy that back up when everything else is ready.

 

The last two big things is the external gate and the throttle cable :)

 

[Taz_Rx]

Highly reccomend removing the sump from the engine to do your oil return. :yes: