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 Post subject: Re: 1.1 turbo
PostPosted: Tue Jul 30, 2013 11:41 pm 
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This project is well on the way exhaust manifold is nearly complete and inlet is complete with carb fited intercooler has arived and has its place just need boost pipes down pipe and oil feed for turbo and having a spare sump modes for oil return at weekend :)

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 Post subject: Re: 1.1 turbo
PostPosted: Wed Jul 31, 2013 2:25 am 
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Location: County Durham.
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 Post subject: Re: 1.1 turbo
PostPosted: Wed Jul 31, 2013 9:31 am 
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I'll sort is jason i only really use my phone for web and you can't upload pics onto photobucket :/ anybody know of any apps that give u a photo tag to use to upload pics lol ! God forbid i have to turn laptop on lol

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 Post subject: Re: 1.1 turbo
PostPosted: Wed Jul 31, 2013 12:37 pm 
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I use the photo bucket android app, uploads fine. Admittdly its not quite as easy as a computer but would be nice to see a thread on this with pics

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 Post subject: Re: 1.1 turbo
PostPosted: Wed Jul 31, 2013 12:38 pm 
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Postimage.org works from my phone and no sign up required.


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 Post subject: Re: 1.1 turbo
PostPosted: Wed Jul 31, 2013 2:57 pm 
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c6rwn wrote:
I use the photo bucket android app, uploads fine. Admittdly its not quite as easy as a computer but would be nice to see a thread on this with pics


+1

I use the Andriod app to upload the pics to Photobucket from the phone.
Then put the pictures on the forum from my computer.
It's a pain from the phone browser.

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 Post subject: Re: 1.1 turbo
PostPosted: Wed Jul 31, 2013 11:51 pm 
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Location: rotherham,south yorkshire
Well you can see all i had to do to the inlet was dril and tap 2 new holes and file/port match ever so slightly and tha was job done all i need to do to that now is make a throttle cable asembly to work and a choke cable to work :)


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As for the exhaust i decided to go super budget and make my own which so far has cost me £0 and just a few pieces of metal out of my stock pile !!

Not the best but it will sufice for now. !!!

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And the renault 5gt turbo alloy intercooler

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Spendsture so far

Turbo £40 deliverd
Carb £55 deliverd
Intercooler £27 deliverd + £5 for blak paint :)

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PostPosted: Thu Aug 01, 2013 1:15 am 
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impressive so far

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PostPosted: Thu Aug 01, 2013 6:46 am 
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Looks good. I would be aware that there is a high chance of the flange breaking off that manifold after a few heat cycles , this is the nature or welding to cast unless you use expensive filler or propper preheat and cooldown. Also what has happened to the outlet for cylinders 2/3 it looks blocked by your flange?


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PostPosted: Thu Aug 01, 2013 7:26 am 
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Cheers dan

Yellow capri hiya mate yes im half expecting it to drop of but im hoping it will last as long as it takes to get setup :/ ???? Fingers crissed i suppose on that 1 lol

I put a 35mm hole saw straight through the manifold between the teo original putlets so they all come together and then i blocked 1 with the plate

So it might not look like it but all 4 do join up in the flange are iv got a pic to show this but photobucket app is a noghtmare to use !

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PostPosted: Thu Aug 01, 2013 10:55 am 
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Bonkers. Love it.

Also - you are out of kitchen roll.

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PostPosted: Thu Aug 01, 2013 2:20 pm 
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the pigeon that shat all over that manifold probably used it to wipe its arse :lol:

only joking shane ;) , looking good and coming on fast. before you fire it up we all need to have a bet on how many days till the rods make a break for it lol what boost you decided on?

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PostPosted: Thu Aug 01, 2013 4:54 pm 
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Cheers mark and yes i need to get some more rolls lol :)

Haha droptoplopchopeokshop

It was my first time welding cast steel so i learnt alot quickly like its no easy lol and the thickness is a pain as te flange was 8mm and the manifold ib places is like 15 mm thick lol !!!!



Tbh im going to have the other manifold i have done the same but profesionaly tbh as the turbo locstion is perfect !!!!

Local fab shop has nickel rods and equipment to do pre heat treatment and blankets to wrap it all up in after so it cools slowly :)


Its coming ob quickly but only due to bargains poping up !!! ;)

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PostPosted: Thu Aug 01, 2013 4:55 pm 
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Oops sorry as for boost i wanted 7 psi but id push a bit more if the tuner deemed charge temps safe and it wasnt deting etc supose it depends also on how dizzy behaves ?

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PostPosted: Thu Aug 01, 2013 7:49 pm 
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If you use the nickel rods you don't need to preheat as much but they are approx £5 per rod last time I checked, you can use cast rods which are cheaper but you need to preheat alot more.

You can use mig on cast but you still need to prep everything propperly and just do about 3/4" then let it cool down while tapping it with a hammer then grind the end and do the next bit. This is a very slow process but is a tried and tested method if you have no other option.

Even after all this your manifold is still only as strong as the original part which wasn't designed to hold the weight of a turbo.


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PostPosted: Thu Aug 01, 2013 8:46 pm 
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I'd probably have made an adaptor to mate the turbo to the ohv manifold.
No issues with cast to steel welding then.
But I like where this is going.

Jason.


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PostPosted: Thu Aug 01, 2013 8:54 pm 
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only one way to find all this sh!t out though, crack on Shane :)

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PostPosted: Thu Aug 01, 2013 9:25 pm 
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mate its not bad :) yeah i know its a f*cker to do (bang it in the oven on full to pre heat then when welded chuck it back in and drop the temps slow) not perfect but hey lol
last bit of cast i did was years ago welding a water jacket around a series 1 ally cooler but that was with a tig machine and foot pedal so i gradually heated it then when done slowly backed off obviously that didn't have to take the stresses of a manifold though.

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PostPosted: Thu Aug 01, 2013 9:42 pm 
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Cheers for all info on welding lads i'll take that onboard.i couldnt make an adapter due to angle of flange would have made making a downpipe near imposinle with my limited skills !!!

The turbo is tiny lads weighs fek all !!!

Compresor outlet is 35mm ad airfilter hole is 42iirc its for a toy car lol


Iv managed to move rad about 4" over to drivers side and shave a few pipes to make room next mod wil be a 1" shorter altinaotr belt to get alt right ip haisn engine give me room on drivers side for a slim line fan :) then room iv made on pasenger side is just enough for the intercooler to fit nicely :)

Im loving all these free simple mods so far :) lol !!!!!

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PostPosted: Thu Aug 01, 2013 10:24 pm 
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could make a brace from turbo flange bolt/s to manifold studs for added strength but im sure with a decent exhaust flexi it'll hold up :)

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PostPosted: Fri Aug 02, 2013 5:48 pm 
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Ye thats a possible idea mate :) what i might do is do a down pipe and brace downpipe to a gearbox/engine bolt and then after that a flexi and out of side of car o think im going to try and go down and under turbo acrros top of gearbox cradle out thru chasis leg and out of wing infront of wheel :)

To keep weight down on an exhaust and expense on a new system :)

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PostPosted: Fri Aug 02, 2013 7:09 pm 
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yeah thats what im doing on a zetec right now , making a solid bracket to hold the back end of the 4 branch then a flexi from there.
youre fitting a dv right? 8)

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PostPosted: Fri Aug 02, 2013 7:36 pm 
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Ye sempt best way to me :) erm i wasn't planing on runing 1 mate why :/

There like £30 and t piece wil be about £15 thats £45 and im on a budget lol

See if a bargain comes along maybe ;)

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PostPosted: Fri Aug 02, 2013 9:10 pm 
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this is why i love this forum crack on shane really interested to see how this works out

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PostPosted: Fri Aug 02, 2013 9:51 pm 
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why ??? ........ ffffffftschhhhht ! ... need i say more? :lol: you know how amber indicators/duran duran/satin adidas budgie smugglers are back in? well dump valves are right there with them mate.

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