Twin Seq. Dry sumping for beginners :D

[hoshy]

.

Got an e-mail from my metal supplier last night to say the ali sheet I've ordered is in the post so I've got everything crossed for it turning up today.

Does that include the metal for my little project

[Turbo-Brown]

He said that was going out next week, but the ali hasn't arrived so it's not gonna for the weekend either way


Been thinking about the fuel rails of late as that's the next job to do to get the manifold finished.

Something strikes me as being an important difference between the early B25 rail and the late one which is that the early is a through flow design with fuel entering at one end and the FPR at the other, whilse the later one has the fuel entering right next to the FPR.

Can't see why they'd change to what is an inferior design where the fuel just sits in the rail gathering heat!

Going to make some amendments to another fuel rail for use as an air balance bar too which the IACV can be connected to.

Looking forward to a good worky weekend I think!

[Turbo-Brown]

Minor progress today, got the throttles all glued together.

Might not sound like much, but the throttles needed modifying to accept the ball bearings as the pockets were fractionally too small, and the spindles needed dinking to make them a press fit in the bearings.




Also spent quite some time making a jig to machine the throttle link arms which bolt through and clamp onto the throttle spindles.

[Turbo-Brown]

Made quite a nice component today; the air balance rail

Learning from the last engine where I cobbled all the throttles together using silicone tube which went here there and everywhere, I thought I'd use a spare fuel rail to do the job properly this time. Also makes it easier to use an IACV.

Started off by chopping the end where the FPR lives off and then making a little end cap out of the bit I'd lopped off:



That diagonal bit in the piccy is what forces the fuel in the later rails to keep circulating rather than just passing from the inlet to the FPR (which is what I'd wrongly assumed happened in the later style rails)

Anyway, then machined up bosses for the following:

Idle air
Brake servo/booster
MAP sensor
Boost gauge
Dump valve (the conical one)
and finally the FPR.

If anyone can think of a tapping I've missed then please post!

[Yaninnya]

If anyone can think of a tapping I've missed then please post!

Blanking injectors bosses?
Jan

[Turbo-Brown]

The injector bosses are going to be connected via a little stub each into the inlet manifold so that idle air can get from the rail to the engine and vac/pressure signals can get to the various sensors and brake servo

[Turbo-Brown]

And here are the little stubs which the air passes through

Gonna make the injector bosses tomorrow hopefully and then fire up the welder to get them all stuck in place

[appletree]

Might be a daft or obvious question but were do the injecots go? or havent yo weled the boss's on yet??

[Turbo-Brown]

I quite like to put the injectors underneath where they're a good long way from the head.

Will do the bosses today once my hangover subsides

[appletree]

Working with a hangover is dangerous, you always end up missing somthing or making a silly mistake

[Yaninnya]

Alex,
I'm just thinking: how you going to top up the engine oil?
Jan

[appletree]

Think he's made it so you can still get to the cam cover cap without removing the charger cooler

[Turbo-Brown]

There ya go, easy peasy




Spent about four hours making injector bosses today!

Started off by cutting a curve in the ends of some 3/4" bar so that they'd sit nicely on the runners:




Then gave them all a nice smooth bore for the O-rings to seal against, plus a generous chamfer so it's easy to get the injectors in!

Finally, did about half the welding for the injector bosses (ran out of gas ) and welded to air bosses on too.






Had a good long head scratch before welding all those bits on though and arrived at the conclusion that there wasn't enough room to get the fuel rail and injectors in underneath the manifold as the throttle linkage would be in the way, so the injectors are now on top with the air rail underneath. No real biggy except that the injectors are a little closer to the head than I'd ideally like.

Like all things though, a compromise needed to be struck between what I want and what's achievable

[Turbo-Brown]

Not really an update as such, but have had the mother of all hangovers today so thought it might be a good idea to not drive!

Instead we fitted my upgraded Emerald K3 to my mate's Mi16 engined 205 (his car had an Emerald M3D) so that we could play with the self mapping features.

Pleased to say it works beautifully!

Just make an AFR target table for it, tell it which map sites it's allowed to change, tell it how much it can change them by and then go out for a drive.

I'd forgotten just how many things there are to set up in a new ECU though, throttle position sensor, CPS type, trigger wheel type and offset. Took about an hour and a half!

Still, pleased with the result and happy to entrust my new engine to the mapping software when the time comes!

[appletree]

Alex will the new ecu update its self/alter the map ( within given tolerances) contiusly in the car or only once when you set it up?

Just thinking for change of fuel or excessive temperature change....

Think mines got the ability to but i havent linked a lamda sensor to it so its a closed loop system

[Turbo-Brown]

It generates correction numbers in a seperate map which are applied to the main fuel map. You can tell it to zero the corrections and apply them to the main fuel map.

That's the adaptive mapping function, or you could just set the idle site to say 14.7:1 and set that one site to closed loop.

All good fun and worth having a play with.

[Turbo-Brown]

Ah haa!

Thanks to the magic of ebay, I've just bought a nice 525tds gearbox for the princely sum of £78 delivered

Apparently these are the 'boxes to have to deal with big torque so that's one more worry crossed off the list!

[Turbo-Brown]

Actually, it's probably not worth setting yours to do any adaptive stuff thinking about it Matt as Dave Walker mapped yours didn't he?

Only thing you might consider is setting just the idle site to closed loop.

[march109]

Ah haa!

Thanks to the magic of ebay, I've just bought a nice 525tds gearbox for the princely sum of £78 delivered

Apparently these are the 'boxes to have to deal with big torque so that's one more worry crossed off the list!

Is it deffo a e30 325tds gearbox? as I haven't been able to find one anywhere, though its less of an immediate concern for me.

[Turbo-Brown]

Nay! It's a 525tds 'box

As luck would have it, there was one on ebay the day I looked!

[maxfield]

Did I tell you one there was one on the floor at college?

[march109]

Did I tell you one there was one on the floor at college?

Does it work? Is it for sale (at a rasonable cost)?

[maxfield]

Yeah, it definitely works.

As for it being for sale, I wouldn't know. I'll ask tomorrow.

[march109]

You do that, I won't be back online until thurday though from tonight so if it is PM is best and I'll reply as soon as I'm back online. Obviously also collection is probably out of the question so could only purchase it if you can arrange courier.

[maxfield]

No worries dude.

Don't suppose you know any more about the CF bits? PM me, as wouldn't want to spam the thread

[march109]

PM on its way gimme 10 mins.

[Turbo-Brown]

So was it for sale Max? Just out of interest really.

Eeeeeeeeee!

Just ordered a set of Eagle rods (and another set for March109 too ), a MLS head gasket to suit my 85mm bore, ARP Main studs, ARP head studs (would much prefer studs to bolts for the head!)

Next major engine component would be the cam I guess.

Still thinking about the rockers. I'm deeply tempted to have a go at making a set, the only difficulty is the pad which bears against the cam itself, the rest of the component would be very simple to manufacture.

[maxfield]

No, it's not for sale

It's being used for working out transmission ratios at the minute.

[Turbo-Brown]

Would they swap it for another gearbox do ya reckon?

[Turbo-Brown]

Holy crap, just had a thought!

Couldn't tell me what the ratios turn out to be could you Max?

[Turbo-Brown]

Awesome!

Just got to work and the flywheel has arrived (4 weeks late ) Looks gorgeous and weighs next to nothing although I need to check it against the sample I sent them (which hasn't come back for some reason!) and the clutch too.

Then I can order the driven plates! Oh excitement!

Piccies to follow

[Turbo-Brown]

Well bugger me! The gearbox has just arrived!

[Turbo-Brown]

Mixed news from today's haul. The clutch fits the flywheel (sigh of relief!)



And the flywheel itself looks gorgeous! Love the scalloped back! The engine should spin up very freely with this on it I think!






Got the 525tds gearbox too, but it looks like it's been dropped in transit and the shitty casting (my M3 'box has done the same!) has broken.



Don't think it's a complete write-off though as I can probably bend up a 6mm plank of steel, attach it to the good mount on the right hand side of the 'box and then drill and tap a hole in the thick part of the remaining mount on t'other side and attach the mount to that.

Bit of a palava but I guess you can't expect perfection for £78!

Will have to see what the ratios are this weekend too!

[Karan]

ello mate i dropped my m5 box and did the same thing... took it, and the piece to my local ally welder and he just welded it back on trying to not heat it too much so as not to warp the output shaft seal area

as u TIG neway, just weld it!, mines still on, but not as much broke as ures

[Turbo-Brown]

Welding it did cross my mind, but I happy enough that a good M8 bolt into the remaining bit of the casting will be fine.

God knows why the castings are so brittle! Presumably it's some grade of aluminium which is ultra stiff to prevent the gears seperating under load or something, but deal with shock loadings it sure can't!