M30 Turbo conversion

[Rav335uk]

NICE!

[staley_turbo]

Engine wiring loom done. Sensor loom nearly done. Oilcooler, rad, intercooler and fans fitted. Magnecor Custom 8.5 leads. Map sensor and FPR mounted. Tonnes of work done and to do. Some pics for you.

[baptie0]

looks mean

[Morat]

That thing is going to FLY!

[ImysE30]

Good progress, gonna be awesome and rapid when complete

M30 Turbo FTMFW!!

[staley_turbo]

Since being let down buy the company who was making my manifold, i decided to make my own. This is only a temp one until i can find someone else to make it to the standard that i want.
I have spent all week on this and im happy with the results for a DIY job.

[staley_turbo]

Fitted to car.

Loads of room for a down pipe..... not.

[ImysE30]

Looks pretty tight, checked out the clearance for the steering?

[Rav335uk]

That is fookin' tight

[staley_turbo]

Its not the biggest gap is it I have 2mm clearance if i use 2.5" downpipe - and i was planning on using 3".

[Rav335uk]

Did you use all manderal bends??
And what did you use to weld the stainless with?

[staley_turbo]

Yes all manderal bends and used tig. Its not the best but it will do to get her going.

[Rav335uk]

What turbo you using??
Or have I missed that somewhere?

[staley_turbo]

Its in here somewhere. Super t70 turbo. Its a biggie

[Rav335uk]

Its in here somewhere. Super t70 turbo. Its a biggie

[leeparkes]

Fitted to car.

Loads of room for a down pipe..... not.

Id try and shorten it on 4,5 and 6 to bring it closer to the engine.

This sort of fashion


http://www.turbochargingdynamics.com/pr ... nifold.php

How much power you expecting to run?

[staley_turbo]

Its ok, i can fit in what i need to. The next manifold will be a better fit. Hoping to run a healthy 400. Anything more i will be very pleased but until i buy internals i wont be going silly. This is only the first step, id like to get it running spot on, get all issues out the way, mot and drive for a good 6 month to find problems. After this i will start again.

[Rav335uk]

Appaerntly, you can run 500bhp on standard internals.
I posted a link to a US forum with the guy running about 550bhp on standard internals.

[staley_turbo]

That's asking for trouble, but it does show what a fine engine the m30 is.

I was thinking in the longrun weather to do things properly and upgrade before turning boost up or just turn it up till it goes bang - then upgrade.
I don't actually see many people upgrading internals when forcing air in, unless there going for silly power.

I know toby threw a rod on one of his engines, but he was using basic engine management and the engine had done around 300k

[Rav335uk]

Imys got that engine now for his cab.
I spoke to Gunni a while ago on this, he reckons 450bhp is no problem for the M30 internals.

[staley_turbo]

its not the engine that threw a rod but yes he has got the better lump toby used. Well lets see what my lump will do

(this is my 500th post ) edit - nothing on you though rav

[ImysE30]

Let's see what they both can do

You'll get yours finished quicker than mine though

[Rav335uk]

its not the engine that threw a rod but yes he has got the better lump toby used. Well lets see what my lump will do

(this is my 500th post ) edit - nothing on you though rav

And 5 yrs

[DRIFTBOY]

Very nice!


A word of warning from experience though, and Imy - take note!

You might want to shield the abs lead, and inner wing grommet, that runs to the driver's side front brake, mine melted with the heat from the turbo!

Good luck, looks a great project!

[staley_turbo]

Ill be moving everything away. The manifold i had ordered was meant to be ceramic coated which the next one will be, + downpipe and maybe even turbo
Not on my shite manifold though.

[GeoffBob]

Great work Staley. Only just spotted your thread, great read.

I welded up both the inlet and exhaust manifold on my engine from stainless "dairy bends". Looks similar to what you have used. I now need to add an external wastegate to the exhaust.

One tip if I may be so bold - by flooding the inside of the pipes and bends with Argon gas you can stop that horrible slag/crud from forming on the inside surface of each weld. It requires an extra bit of hose connected to your flow regulator (or a second flow regulator if you have one). You then feed that second hose into your workpiece and block of the entrance with a bit of rag or similar (something to help the Argon fill up the inside and not just blow straight out. Technically, it's called purge welding, and relieves you of the necessity to grind down the welds on the inside of your pipes with special tools.

Still a good looking manifold BTW. Keep up the good work, I'll be following your thread from now on.

[staley_turbo]

What a good idea, if i only new last week Ive been grinding the inside for days

[GeoffBob]

What a good idea, if i only new last week Ive been grinding the inside for days

No worries Matt. I've been there and done that. I once made up a set of special grinding tools using 3/8" steel tube (bent down the tube I was trying to get inside) with a length of stainless wire cable down the inside of the steel tube. I welded a grinding tool on one end of the cable, and put the other end on the chuck of a drill. I then carefully welded a "handle" to the side of the steel tube to stop the whole affair from spinning aimlessly. Even with a lot of grease down the inside of the tube the cable didn't last more than 20 minutes at a time (so I made up a few I can tell you), but it got the job done.

Unfortunately, any roughness down the inside of the header tubes will make your flow turbulent. If the roughness is severe it can go so far as to restrict flow. I wouldn't worry too much about it though. It's not as though it will stop your engine from boosting . What I would suggest, however, is that you make sure that there are no loose bits that could potentially break away into the exhaust flow, as these bits could do severe damage when they pass through your turbine blades.

[keri-WMS]

What we need is somewhere that'll do one-off extrude honing (aka Abrasive Flow Machining) jobs on our DIY manifolds!

See: http://www.extrudehone.com/gallery-box/ ... uto&id=197

[staley_turbo]

Turbo is on.



Engine bay is nearly full

[shedrool83]

Looks great .Loving this thread.

[kieranbusak9]

awesome job mate! you should be proud of that manifold...its an achievement on its own.

[staley_turbo]

Im not too proud of it to be honest mate, but it will do for now.

[staley_turbo]

First start, still needs mapping. All good so far.

[ImysE30]

Nice