Tuesday, September 17, 2013

Turbo and manifold - first look

I eventually gave in and made a deal with the guy on the Vortex for the BBM throttle body adapter. While I still feel it is quite expensive (the most expensive part on the motor so far) I believe my amateur attempts at welding something that sophisticated would have failed, or at least taken a long time to complete. After thinking about it for a while I decided I'd rather not have the entire project sitting idle while I debated whether I could make a CNC machined part out of a Dremel, scrap metal and amateur welding skills. This is something what it should look like:


Since I am now pretty comfortable the motor runs as it should in naturally aspirated form, its time to get going on the turbo. The first step was to piece everything together and get a rough idea of how it will fit. When I was choosing the manifold, I wanted something that kept everything at right angles since I thought it would keep things simple, and the downpipe I acquired already had a right angle on the wastegate from the turbo exhaust flange, so I thought it might get lucky and it could actually fit. It may turn out that this was a bad mistake. Since the turbo is sticking straight out from the cylinder head, it requires more room than it may have require more room than if I bought a manifold with an angled flange. My rough measurements suggest it may just squeeze in place - but if I could do it over I would buy an angled flange.

I then rebuilt the turbo charger itself to realign the charge pipe. Its original position would have pointed straight back into the exhaust manifold, so I realigned it such that the charge pipe points straight up parallel to the cylinder head. This configuration should allow for easy intake and charged piping.

Piecing everything together I began to think about how I would run the wastegate's boost line and the coolant and oil lines.

For the boost line, there is already a nipple on the charged side of the compressor that I could simply run to the waste gate, however, this would leave me with no control over boost aside from the pre-set spring included in the wastegate, which I am not sure what its set at. This leaves me a choice of running it as described as a temporary solution to get things running, or perhaps warrants the search for a boost controller on the forums somewhere. Ideally I'd find an inexpensive boost controller that I could run the lines for before everything gets installed to avoid any difficulties working in the tight spaces later.

For the oil lines, I can run the oil intake straight from the oil filter housing. There are two spare bolts on the filter housing I could screw a threaded adapter into - unfortunately I stripped both the bolts out trying to remove them, which means I'm now likely committed to a thread removal tool - I'll see if I can find one to borrow. The oil return line will need to be tapped into the oil pan.

Last is coolant lines, for which I have no idea how I am going to run. One option would be to tap the side of the cylinder head. I'd rather not take this approach since an error would be catastrophic to the whole project. Off the top of my head - I'm thinking an adapter on the flanges - both in and out, is the best solution for this.


No comments:

Post a Comment