darrenjlobb's Adaptronic Managed Compound Blown Derv Bus Build

[darrenjlobb]

Time for another update,

Been working on getting the manifold / turbos fitted to the motor, largely this is the same as on the mtdi setup, however the GT2256V has been replaced with a GTB226VK, HX30 remains for the time being however, although will likely be replaced with a big BW at some point into the future.

Anyway, started by roughly bolting the manifold up to the head to see how things were looking, as things were likely to have moved welding on the new turbo flanges / pipe arrangement, and things were extremely tight before!



So first problem was fairly immediate, small clearance problem with the water flange, had two option here, either cut up the manifold yet again and tweak it, or modify the water flange for clearance, decided to do the latter, to avoid having to re tweak all the suport brackets etc for the manifold, as change one thing, and nothing else works!

So chopped the offending outlet off:



Put an angle into it, and welded it back up:




Then decided to weld in the boss for new EGT probe, and also two wideband boss's one in the ideal situation before primary turbo, and one after just incase of temp problems with the sensor. One will obviously just have a bung in it when not in use. Have got an Innovate wideband controller and gauge which will come into play further into the project.

Started by hogging out the holes:










Next up was to modify the down pipe, the engine before in MTDI form ran a small 2.25" temp downpipe at the time as just needed it to work for testing, I have now replaced this with a 3 inch item, however routing this down and around the back of the motor is likely going to be a fairly big nightmare, as was a big enough issue before. So decided to split the first part of the downpipe off the turbo from the rest, so it could be fitted as two parts, making fitting / removing much easier, and will allow me to fabricate the downpipe once the motor is in the car on the mounts. 
So welded a v band on the engine of the turbo dump:



All welding / tube is 316 stainless for anyone interested, bar the first pictures of wideband bosses where there was an epic fail with the wrong wire in welder despite correct gas bottle being on the welder,! Result was hacking it all back off and starting over, but no photos of that!!

Next up was to get the manifold bolted on properly. Decided to replace the bolts I was using before, with some studs to prevent wear / damage to the threads in the head during tightening, head owes some money now, so precautions taken in course!
So cut up some stainless bar and dressed up the ends:



And bolted her up fast:






Followed by attaching the blowers etc:






Also fitted new valeo alternator, and remaining oversize 8 rib pulleys:



Thanks for reading