Rotrex M42 Build - 285bhp little update

[cliffybabe]

i like the idea using wood to create a template thats qualty

[appletree]

Ya its a good idea as its easyer to work with, costs less and means you get a realy good idea were things will fit

Ive had to re-think the outlet position/direction as it ment the pipe work would be very close to the power steering pump.

origanaly i had planned to run the pipe work streight down to below the PAS pump then through a 90 bend forward then a 90 right to get to the driverside of the car then a 90 in to the intercooler.

With the new position with the new positon pointing upwards i need a 135d bend streight after the charger pointing diagonaly down to the bottom front of the drivers side then through a 45d bend to the intercooler which i think will be better and will also mean i have more space to work. all this means is i will have to heat wrap the pipe work as it will be passing were the viscous fan used to be behind the rad.

Heres some pics of the final mounting position using the wood mock up, hopefully ill get some 10mm plate at the week end and start on the final metal one.







Going to be nice to swop back to the original resivours for the pass and the brakes as i had to swop them for the first set up, think they're off a Cav turbo





Heres two pick of the bracket/mount this will be made from two peices of mild steel welded at the corner and then a gusset made to brace from the front to the back of the mount to reinforce it and then maybe a pair of ribs under neath.






Also got my 540 v8 throttle body today, post some picks up later its massive! maybe to big!

[DieselMeister]

Nice work

[Phill172]

looking like some serious bit of kit! Really nice work on that plenum too!

I really need to learn tig welding!

[e30_Turbo]

Is that the double chamber one? oval shaped?

[Ant]

looks sweet as Matt

Wood rules for templates,

Tensioner ???? it MUST go before the charger

PAS on the 6 rib too I assume from the pic( looks a little bit out of line btw)

Nicely done

[appletree]

Thats right at 6v pully, was thinkin of making a pully for the power steering pump to bring it back in to line and then use the power steering as a tensioner, should still have enough belt wrap. Any thoughts?

Or is there any chance i could borrow one of your sprung loaded ones to mock up Ant?

Which do you think would be best? I would also have to run another pully for the PAS if i run a loaded tensioner

[appletree]

Is that the double chamber one? oval shaped?

No in the end i kept it as one large section.

[rix313]

Selling any bits from the Eaton build?

Whats your plan for cooling on this one?

[appletree]

At the minute i'am not selling any bits from the eaton build, or at least until ive proven this ones good

For the charge cooling i'am going to be running an intercooler

As for the water cooling the standard rad worked fine on this set-up so i can't see why it wont work on the new one

[appletree]

Little bit more progress today, managed to get a belt from halfords that fitted perfectaly, its lucky its the right size as the only other 6V belts were twice as long.

Heres the picture to show the belt run and were tensioner will go althought the tensioner will be adjustable and will be mounted on the outside of the belt with the roller inboard



Not sure wether to use the standard power steering belt or keep the flat belt i'am running at the minute as the standard belt gives more space

[appletree]

Few pics of the progress ive made this week and last weekend.

A pic of the charger on the wooden mount with my new silicone bends showing the rough path of the pipeing as its got to get to the otherside of the car.





After the wooden template showed the mount would work ok i set too and started to make it out of metal.

had to use the big lathe at work as dads was to small at home.



fare sized chuck as you can see! nearly gave my self a hernia lifting it on!




A few pics of the mount made up, i decided to bolt the mount togeather as i realy didnt want it to distort throught the heat of being welded.

Just dropped a square over it and its as square as a square thing!

Just need to drill the holes for the charger to bolt to it now as i need to check the angle of the charger as they have to sit level within 15degrees

The pics












.

[e30_Turbo]

Very nice!!

I had a special job today at work, we pack up race engines for a local builder, they usually top spec duratec or zetec race lumps but today's was a little different, a 1300cc hayabusa bike engine with a rotrex c30 strapped to it!!

The power is unreal, well over 400bhp, wouldn't say as it's going to be tuned for more!!

Being a proper race setup it had dry sump, unreal exhaust and collector and a IC that plumbed into the TB's, I have pics but daren't post as I don't want to pee them off, they're quite secretive about there engines.

I had a really good chat with the owner of the company, as I always do, he does all my machineing so best to keep them sweet, stole as mayny ideas as I could, some of the solutions are sweet.

On another note, I picked up a few m2 of 1.2mm stainless steel sheet, brushed one side too, just pipework to get and I can start on the inlet manifold!

[appletree]

Great stuff mate are you wanting me to get the bends for you? if your not to bothered about the odd scratch that will polish out i could probly chop a few of the scrap bits at work if i ask the gaffa , they'd be in a simular condition to the ones i used

[Phill172]

wow

that is some seriously good machining, looking at my build compared to these i feel like a honky tonk from the deep south in the states!

that design for the belt and bracket looks like bmw should have done this out of the factory!

top work!

[appletree]

Cheers, theres abit more to do around the tensioner side of theings to make it have more movement but its all but in place

[rix313]

As said i'm keeping with the supercharger as i love the respose and the noise, (

Just picked up on this bit, the rotrex chargers don't make the know super charger whine but have the loudest induction sucking noise lol

[appletree]

A quick pic of the metal bracket mounted to the engine, ive had to use so 30mm spacers between the block and the plate to make the plate miss the oil filter housing.

But here it is anyway,


No this is bolted on ive been able to work out were 15degrees off level is and drill the mounting holes for the charger, so thats another little bit done

Ive been working away on site again and had a nice suprise when i got back! shainey bits


My intercooler i orderd from the link "e30 turbo" posted had come as well as a very nice turbosmart BOV

The BOV was quite dear and once i bought it i did think how much better could this be than a forge or bailey item?? well the answer is alot better you realy can see the difference in quality i also managed to get the 25mm fitting kit for the valve which will help the flow of boosted air better.

Only thing i do want for it is another trumpet instead of the part recirc port.

[e30_Turbo]

Nice IC! Jon looked after you then?

BOV is sweet, expensive stuff them turbosmart bits, my BOV is 4yrs old and going strong, gave it a clean the other day, oiled a little, dumps much happier now.

Did you measure the wheel in your SC? I had my hands on a 97mm compressor today, 80mm turbine too, could barely lift the turbo of the desk!

[appletree]

ya he did thanks mate!

i forgot about your bends! i'll go in early tomorrow and sort it for you mate send Pm me your address £25 inc p an p

[e30_Turbo]

just need an address!

I'll send you mine

[rix313]

What type of diff have you got?

[appletree]

3.91 LSD tryed a 3.64 but it was to long.

[rix313]

Another thing to add to the list grr lol

This is going up and up.

[appletree]

Been working on the car all day and ive got the front valance cut to suit the intercooler and the intercooler mounted. to say its tight is an understatement!

i tryed to fit it the other way up but the problem is theres not enough gap to fit the 3" deep core in, you might gataway with a 2.5" one, so i had to fit it the other way round!

ive had to remove the inside head lights, does any one have any ideas how i can run a all in one head light in the out side slot??

Do you need them both for an MOT????

Anyway heres a few pics

heres the bracket for the bottom made from a bit of stain less angle.


The front pannel cut primed, painted and waxoyled

[e30_Turbo]

You need a H4 backhalf glued to a e30 light, bandsaw, glue sorted! Golfs had what you're looking for, no you can't use the golf front halfs as they're twice the size!

I bolted on VW golf mk2 full beams, straight onto the bumper, MOT man says ok.

Are you going to hole the front bumper? You are now where I decided to cut the fecker in half!

[rix313]

So its ok to bolt head lights on the bumper and remove the inner head lights ?

[appletree]

You need a H4 backhalf glued to a e30 light, bandsaw, glue sorted! Golfs had what you're looking for, no you can't use the golf front halfs as they're twice the size!

I bolted on VW golf mk2 full beams, straight onto the bumper, MOT man says ok.

Are you going to hole the front bumper? You are now where I decided to cut the fecker in half!

So you put the golf ones on just for the MOT then? And drive without main beam?

Or have you cut the back off a golf set? Pics if you have please or was that just an example?

Not sure about the bumper think i might leave it and see what temps are like when driving with or without the bumper. Then i might hole it or half it! Going to put some plastic sheet in the bit above the cooler to stop the air flowing over it.

[e30_Turbo]

So you put the golf ones on just for the MOT then? And drive without main beam?

Or have you cut the back off a golf set? Pics if you have please or was that just an example?

It's been done but I live without, use horn a bit more but overall being a good careful driver I get by just fine

[ShepsEvo3]

As said i'm keeping with the supercharger as i love the respose and the noise, (

Just picked up on this bit, the rotrex chargers don't make the know super charger whine but have the loudest induction sucking noise lol

They make the exhaust note sound pretty awesome too, a load sound of air being forced out the tailpipe

[appletree]

Dam i forgot to ring you back paul! I will try you again when i get a minite

Any links/how to's for the lights?

[rix313]

Can ya link me up to where ya got the cooler from please bud

[appletree]

Coller?? Do u mean the intercooler? It came from jon at maximum powered on ebay £99 780mm wide 600mm core.

Theres an old link earlyer in this thread.

[ShepsEvo3]

Dam i forgot to ring you back paul! I will try you again when i get a minite

Any links/how to's for the lights?

Can you fit the intercooler upside down so the pipe work is behind the valance and not the main beams? This is what I was going to do with mine, still have it high in front of the radiator, but deep so I was going to fit the A/C front valance with the extra air ducts.

Also, with the IC inlet and out being on opposite sides is why I wanted the SC on the exhaust side where the A/C compressor would have gone. I know you have already looked into this but thats why I thought it would be an easier way to go initially.

No worries about the call mate, I was going to call you back but my phone doesn't save missed calls/recieved calls, etc so couldn't, just call me when you can or txt me and I'll call you back

[Phill172]

haha fozzy fitting the golfs lights like that is brilleant! i was starting to get stumped thinking about the mot time! appletree the builds looking brilleant! youv made everything look so easy