Twin Seq. Dry sumping for beginners :D

[appletree]

Went to the autosport / Piston heads show the other weekend and saw some things that might be of intrest to you!

I know your abit further on in the build to realy need these but here yo go any way.






probly the most useful one thats blurd




And for your next project!

These were quad turbos for a Evo! bet theres not much lag!

[BigPerformance]

Those quad turbos are a variant of the GT12 that are on smart cars(which I tune BTW).
They are great to play with.

[Turbo-Brown]

Crikey, that little package of two turbos looks complicated! Guess the basic prinicpal of operation's similar to what I'm doing though. Did they say what it was intended to go on?

Think the multiple turbos doing the same thing causing less lag is a bit of a myth to be honest. OK the turbos are smaller and have lighter internal bits, but they're also only getting some fraction of the energy that a single turbo would

Now a twin sequential system, that shouldn't have any lag (if it works!!!)

[Turbo-Brown]

It's been a productive day! Got about half of the charge cooler done now!

Started the day by making a turning vane for the inlet side and welding that in:






Then welded on the last piece of the outer shell of the "toothbrush"




Before doing a little bit of fettling so everything fitted nicely and wiring the toothbrush to the core:




And finally set about welding the two parts together, welding over the holes which were in the outer plates of the core at the same time.










Going to make up the cradle which holds the cooler in position tomorrow. I've got some little rubber bobbins to mount it on so it shouldn't experience too high a level of vibration. Having made the cradle I can get on with the other side of the cooler.

Even had a quick go at making an inlet trumpet today, it's surprisingly easy! All you have to do is machine up a piece of steel to the shape of the trumpet you want, put a length of ali tube over it and then clamp it hard in a vice!

[gareth]

looking good dude!

[Turbo-Brown]

Cheers Gareth

Been a bit of a mundane day work-wise. Was going to do an ECU upgrade for the Mi16 but thought better of it as I've not read the instructions properly yet. Instead I took it out for a drive over to the parents' house. God only knows how my mate's been driving around in it as the clutch would only just disengage! Had a quick play with that so it's a bit easier to drive and modulate the clutch now

God I miss manual transmission and throttle bodies! It's just so easy to rev match and heel and toe changes are a doddle with the wizzy little four-banger

Anyway, I digress

Here's the little test trumped I made yesterday, together with it's former. It was just done as an experiment which is why the former's not got much of a rad on it. When I do the trumpets proper I'll buy a bigger bit of steel and made it shinier and have a much larger radius.










And also got a little bit of the charge cooler cradle done. Was going to have the cradle straddle the head but it seemed easier to have a pair of bars run the length of it instead. Will mount the turbo brace on the cradle too.

Here's the little upstands for one side:




The length of ali channel being used for the spar with a semi-circle cut at both ends:




The bits ready to be welded together:




And the cooler and cradle in position:

[Andy335Touring]

It's comming along quickly now, you'll soon be on the road at this pace !

[d6dph]

Amazing thread Alex. Really interesting and mostly waaaaaaaaaaaaaaaay over my head (Not just because of my less than average height)

[Turbo-Brown]

I wish there was light at the end of the tunnel, but there's all the bodywork to sort out, and I've decided the inlet manifolds I've made aren't good enough so I'm gonna start them again (this is all because Oakey's manifolds came out so nicely! )

It'll be better for it though in the end, just more work to do though.

Anyhoo, cheers guys! The encouragement I've been getting from the forums is quite a large part of the motivation to keep things moving!

[jkarran]

It's always worth re-doing work you're not happy with even if it's bits nobody will see. You'll know it's there and it'll bug you (well, they bug me anyway!).

It's all coming together now. but the 'little jobs' all take ages don't they. I just spent hours machining part of a gear shifter that nobody will even look twice at when the job's done. I could have bodged the job in any number of ways but I wanted to do it right... doing it right takes time and you occasionally have to start over but in the end it'll work better, look better and be better

The ali welding is looking great by the way.
jk

[Turbo-Brown]

This is it, I could spend ages trying to rectify the mistakes I've made or just start over with a clean sheet

So what part of the gear shifter are you making JK?

I've been thinking of ways of putting ball-races into everything in the shifter mechanism to eliminate all slop and improve the feel of the shift. Probably a bit of a case of "law of diminishing returns" but I've been searching for that elusive metallic 'snick' ever since I took the GT6 off the road!

The welding's a bit variable (which doesn't show up in the pics ) where it either looks stunning and I get all smug, or I repeatedly dip the electrode in the bloody pool . Such is life though

Will have to dig out that power supply and see what the MAP sensor gives as an output before long too!

[gareth]

as an off topic, my shifter is virtually free of play. i replaced all the washers and the joint into the 'box and fitted the 1.9 z3 stick but there was still play. a bit of investigation traced down some intentional play in the stick itself (two part, rubber isolated jobbie) and some movement in the suppert for the mechanism that lives behind the shifter hole. i bulked up the diameter of the shifter mechanism where it goes into that support bush and it's loads better. about 5mm free play now and very positive. still not the 'snick' 'snick' that an old triumph gearbox gives though but not at all bad. nowhere near as good as a mk1/2 RS 4 speed box with a quickshift though...

[Turbo-Brown]

Perhaps I should just concentrate on making the lever and link components heavier and removing any bits of rubber from it all too.

The last one I did for Brown was nice and positive with the bronze bushes and lead filled link, but I reckon it could be made better if everything was solid steel and ali

Anyhoo, ordered the bits to make my new inlet mani and I've had a quote of about £380 for all the bits to make the exhaust system.

It's all stainless and should give me enough pipe to make a full 3" system and a full 2" system for the wastegate.

Debate now rages in the office over what the tail pipes should look like.

I wanna stick with a twin tail pipe with a slash cut as it's neat and easy to make, but do I go for two 2.5" tails (making the 3" reduce) go for a 3" and a 2" tail which might look weird, or go for a twin 3" which might look a bit chav....any ideas?

[e30_Turbo]

Stick with a single, why complicate things anymore

[jkarran]

Gear shifter is for a friend's Mini I'm doing (I really don't 'get' Minis but I do love hanging bike engines where they weren't designed to go ). I'm giong for a column mounted sequential shifter, WRC style (though mechanical obviously rather than electro-hydraulic).

Sorting the shift in the E30 is way down the list amongst all the jobs that won't get done... suspension is going to get some shiney new bits as it's wobbling around like a drunk at the moment

You've hit on the problem with a big project, your skills improve as you go long so your early work ends up letting it down... so you re-do it... then pick on something else... then it's 2018 by the time you're happy with it and you can't afford the fuel to run it anyway

re. tail pipes: The gas has cooled a lot by the time it gets there, a small reduction in section won't make much if any difference. I was looking closely at a standard R1 can the other day with verniers to hand. The main pipe is 61mm (huge for a 1L engine!) but the tail pipe (hidden by a huge cosmetic trim) is actually quite small (~1.1/2") after the backbox.

[Turbo-Brown]

Hey Mark, how ya doing mate?!

Is that a 3" pipe at the back of your car there? I could live with a pair of 3"ers if that's what they look like

Reason I want two pipes is that I reckon the large turbo wants a 3" full system, and the wastegate wants at least a full 2". Not keen on having a screamer pipe personally

Tis a good point about the gas having cooled and contracted by the end of the car JK but I just wanna give the gas every opportunity to exit in an orderly fashion.

Maybe a twin 3" won't look too bad. Certainly shouldn't attract the same amount of attention that the ICs did on Brown at any rate!

[gareth]

how about a 2" sidepipe on one side and a 3" one on the other?!
that should upset the pureists!

[Turbo-Brown]

Had crossed my mind, but I think having no tail pipe would look even stranger than ones which are just an odd size.

Really wanna keep the car looking as standard as possible at first glance, especially after getting pulled because the front of my car looked "funny"

[Andy335Touring]

especially after getting pulled because the front of my car looked "funny"

Thats why i like them stock looking too, i've never* been pulled in mine.

*except when i went tanking past a copper in a lay by , he had no speeding equipment on thank god but i had to eat some humble pie and take the patronizing lecture on the chin

[gareth]

the 335i touring. the best sleeper e30 possible! if i go out for a 'play' in town of an evening, i can usually make enough noise to attract the attention of the police who will pull over the saxo i've just obliterated as it's the obvious target! i sometimes do it to mates if we're in convoy!!!
i'm thinking about getting some steels (banded ones!!!) and painting my scorpion exhaust matt black for more stealth! i've just refitted my towball too! (for the lpg filler to mount one and so i can tow a track/drift E21!!!!)

[Turbo-Brown]

Did PPC ever do that article about banding steelies? Remember seeing it in the "Next Month" section, but not seeing the article itself.

It's been a bit of a slow day today (or at least it's felt slow).

Got the other mounting bridge made up for the charge cooler and also have managed to weld on two of the mounting points. Going to get the other two on tomorrow and, once the new inlet manifold's made, I can get on with the other half of the cooler.







Slowly but surely!

[Turbo-Brown]

Quite pleased with today's efforts!

Got the other two mounting points for the charge cooler welded on and in the case of the long one, braced up:



And made a little mod to the exhaust valve assembly so that it fits back together properly.

It actually feels like I'm getting somewhere now that I've got some bolt-togetherable components which aren't all trying to occupy the same space

[appletree]

Looks very nice workmanship there, realy impressed with the effort your putting in!

wish i could weld ali! stainless is hard enough for me!

[maxfield]

Feck me!

I can see some dustbins going missing!

[Andy335Touring]

Probobly a daft question but does the bonnet shut OK ?

I wish you were closer so i could see all this stuff in person as it's a little hard to grasp all of the details of your project via the forum.

Touch wood you will be able to come to the pod meet ?

I love that exhaust manifold, can you make me an N/A manifold for my M30 ?

[Turbo-Brown]

Cheers guys, much appreciated

For me, the most tricky part of ali-welding is taking bits together. Once you've got that down it's just like stainless only easier to see what you're doing

Did discover in making those support rails though that hard anodised ali needs a very good clean before you weld it or the oxide starts exploding!

It does all look incredibly high doesn't it! The bonnet definately clears the turbo and with the cooler sitting on the rocker cover, that cleared the bonnet too. However, the cooler's about 8mm above the rocker cover now and I've not had a chance to check for clearance yet.

If worst comes to it, I'll make the engine mounts a little bit shorter.

Just secured a nice Tilton twin plate clutch for the princely sum of £100 too which is one less worry. Should have a late model flywheel arriving this week too which I'm going to send off to Demon-Tweeks as a pattern for a lightweight steel fly which accepts the Tilton clutch.

Think the Bodywork's going to be the limiting factor on progress now as there are little bits of rust to cut out and replace, and then all the CF panels to make which I can't do until the weather warms up.

[hoshy]

Looking really nice Alex!!

Got a blank email from you earlier btw...

[Turbo-Brown]

Oh, bugger!

Sorry about that Ashley, will send it again (if I can remember what it was about )

[Turbo-Brown]

Oooh, got an email to say the pistons have been dispatched

Wonder how long it'll take for them to arrive

Got one part of the components for the new inlet manifold today too, hope the rest arrives before the weekend!

[JazzMan]

looking good Alex, if that were in the Sportster I'd have a turbo shaped hole in the bonnet - at least it would get plenty of air and cooling

[Turbo-Brown]

Guess you'd need a charge cooler shaped hole too Jazz

You know it makes sense!


Been in Dublin over the weekend with work so I took today off to get some stuff done on the car

Got the materials to make the new inlet manifold last week (thanks as ever to Mike at NogginEnd for his friendly and efficient service!) so I set-to with the machines today:

This is the new one-piece head plate after drilling and fettling to clear the thermostat housing:




After cutting the basis of one port:



And having decided the first one was right, cutting the res:




This is the plate which the throttles bolt to. I tried cutting the big holes for the air to pass through in it but it took bloody ages as the hole-saw kept clogging up........so my ol' man's going to finish the job at work for me




And the last thing I had time to do which is a set of translators (well the start of them anyway). The idea is that I make a set of gradually tapering translators which go from 48mm at the throttle to 38mm at the head which matches the port. The manifold at the head is easy as you can buy ali tube of the right internal diameter, but the translators need machining out of solid.......yawn!

[Turbo-Brown]

Bleeeeeeeee, Dad's apparently finished off the job of boring the remaining 5No. 48mm holes in the second plate which the throttles mount to

Just gotta spend about a billion years taking those 6No. round blocks out to the required size now!

[Turbo-Brown]

Double bleeeeeee!

I'm getting some Pauter rods!

Now what should I set my rev limit to?

[Andy335Touring]

Double bleeeeeee!

I'm getting some Pauter rods!

Now what should I set my rev limit to?

300-500rpm past where peak power is it at

[Turbo-Brown]

Good point, just hope peak power is at about 6500rpm again