Stage1 to 3? Because stage2 is for pussies..now with pics for added goodness

[toseland]

Epic build!



Started off with a stage1 time, no IC and standard gt15.  This was an epic build from the offset, I got to poodle and Jonny's house on Friday morning, and it continued through the evening until 11pm Sunday.  

The car is as such now.

IHI RHF5 from any one of about 5million different models of car, from 2.4 to 2.9. This one from a kia  The flow characteristics are almost double the flow of the gt15. In a unit that is almost as compact. This one comes on boost about2100rpm and is making full boost by about 2500rpm. It currently has a standard map this will change by Sunday this week as we forgot to apply the new map hah!

Other specs,  full 51mm boost pipe to the GRS Motorsport front mount IC, from a Seat Cupra and then back up to the inlet elbow. 


Intake is an S2000 paper filter oem and 57mm piping to a short run of 51 to the turbo.

Down pipe is now 70mm stainless mig welded with a flexi, onto 2.25id stainless decat to a single power flow back box 


Generic spec, but accurate EGT and boost gauge. And soon to have prosteve map and manual boost controller, looking for 22-23psi.


The build.



When I get home this post will contain pics, I can't link them on the iPad so far..


Step1.   Subframe out, exhaust off, turbo out, oil line off and then a trip to town..  Of course it was absolutely peeing down for the entire time Jonny was under the car spannering and the minute he had finished the sun came out.



Step2.  The epic oil line, titanium reinforced diamond encrusted oil line was taken to the local pirtek to have a new end put on and procure a new banjo bolt with the most expensive banjo bolt ever.

Step 2a. Front end came off, bumper, slam panel, lights etc, 


Step3.  Turbo offered up and the adaptor plate made and fitted to the manifold, also the EGT probe sensor hole drilled. It was a 1/8 NPT fitting with olive compression seal, so an m9 fine tap was used and sealed nicely. Manifold ported, and smoothed, outlet hole to turbo also made larger to suit the new turbo.



Step4.  The start of the fabwork on the turbo down pipe,  plate cut from high grade stainless 6mm 316 marine grade) and  then shaped, drilled as appropriate for the turbo flange. The turbo has a similar setup tothe td04 with a separate wastegate cavity although it all goes onto one collector.




Step 6. Finishing touches put into adaptor plate, 3hours work alone, and the stainless pipe offered up and cut to suit. Tacked on, and test fit (so far so good) all looking shiney. the small collector from the wastegate side of the turbo was offered up and cut into the side of the 70mm, and tacked on.  




Step5. Again the turbo was offered up, and subframe bolted on..  Gear linkages in the way and impacting the down pipe.. Clearance issues are huge the whole subframe has to come back off and the down pipe outlet redesigned slightly, turbo was welded up properly 



Step 7. Rethink the manifold, involving making the bend a little tighter so it sits a little further away from the linkages and tack it back up..  Removed, revised and all welded up..  the waste gate actuator from the GT15 used- again a bespoke bracket and mounting position to get it to work, does work well though. 

the finished product




Step 8.  Cue next test fit, but first shorten the gear linkages loads involving cutting and retailing the ends on each of the short linkages and the longest one a little, and refitting the whole lot.   The subframe, manifold and gear linkages refitted, still needing some considerable adjustment so it goes into gear and doesnt foul the downpipe


Step 9. The mount itself for the funny gearbox ballpoint linkage thing was also in the way when all was in place, this was moved Down and across out of way of a small spacer (mild steel) about 40mm long (this was later welded on)




Step 10. Subframe back in car to test fit and fiddle with clearance issues and I can't select gears 3 5 or R, so again fiddling with the lengths of the linkages and fine tuning some. 

Step 11. As it turns out that with the shortening of the linkages and all of the other adjustment the large ball had been pushed into the tube on the end of the thickest linkrod (from the gear stick) so that when trying to select gears at the extremes of the movement, they now wouldn't fully engage 5/R and 1/2) so the long linkrod needed to be modified as the tube was fouling on the shaft are holding the ball joint. This involved notching the passenger side of the linkrod significantly to avoid fouling across its full range of movement. 

Step 12. After a few more tests is and me going through the gears for the 39th time for Jonny, we get it all shiney and fitted, however the manifold is still fouled the down pipe.. So a little tapping with a hammer and a dent in the pipe a little.. Sorted.

Step 13. All back off and weld it up nice, shiny polishing and finish the manifold off nicely, remove the turbo and check it all for cracks and holes...

Step 14. Refit the subframe, check all clearances and gear shifting again with manifold and down pipe all welded, and shiny and working..

Step 15. Manifold off, weld on flexi pipe, weld in sleeve and exhaust conversion, 



With everything in place for the time being, start the engine after checking all the plugs and connectors., forget that the power steering is off, and spray ps fluid all over the drive (oops). 



Meanwhile in Gotham City.

inter cooler being fitted,  two tabs fitted (welded onto the lower cross member) for the lower mounting, and two bars made to bolt the top to the slam panel.   It should be noted that the inter cooler had 4 tabs welded on each corner. 


In addition the chassis leg was.. Persuaded.. And the edge of the plastic tab on the radiator shaved down so it would fit but otherwise it fitted perfectly. 

Turbo now fitted, the 90degree out of the inlet is attached and routed across the bulkhead after a little.. Persuasion with a bfh to increase the clearance so it doesn't rub on the hose, and get cold side routed across the gearbox to the IC. Back from the IC to the top inlet, boost hose connected and adapter for the gauge installed in the elbow. All done up with some nice million clamps except two bits which will be fixed this week.

Finally turbo plumbed in..  Next challenge was the intake to the turbo. 

This presented some problems.. Ideally we wanted to route it up above the outlet, across the top of the back of engine above the cold side pipe.. 57mm would have been great, but we simply couldn't get a bend to the right angle.. So.. Cue idea two.  51mm from the turbo up the mount side of the engine block, out under the servo and up over the engine mount.. This then goes from 51to 57 and round to the where the air box sits across the engine bay, into the MAF and S2000 filter. 


More to come

[kentiiboii]

Not read this as there's a lot, but have a word with jack-mckenzie smith on Facebook.
His hdi is stage 3 done all the work him self, so he has lots of advice to give.

[toseland]

Not read this as there's a lot, but have a word with jack-mckenzie smith on Facebook.
His hdi is stage 3 done all the work him self, so he has lots of advice to give.

It's been done lol, turbo was/in mounted in the oem location too.. Sleeeeeper...

[mr_fish]

one hell-of-a weekend!

pictures will be interesting as will performance.

Top work guys. 

[toseland]

now includes pictures!

[Poodle]

Got some good pictures there mate, might have to steal some. Was a good weekend, if a bit much like bloody hard work lol, the awful weather on Sunday morning didn't help. Looking forward to Sunday, want a ride once we've got it properly set up!

[Piggy]

awesome work!!

---

can't help think the exhaust system will be your next restriction mind

[Jonny81191]

awesome work!!

---

can't help think the exhaust system will be your next restriction mind

It was a busy weekend, i need a bigger workshops though

Exhaust shouldn't be too much of a restriction, look at zx volcane for example. 

[Eeyore]

Epic build is epic! D:

[Toms306]

I hadn't read it before the pics so didn't realise quite how much fab work had to be done at the same time...that's a hell of a lot of work for one weekend!! Definitely well done you guys!

[toseland]

Genuinely I think the subframe had come off of the car and been put backon15 times.. I was sat in the car at least 20 going through the gears for Jonny at least 20..

On a plus note the gears are now sweet as a nut, shorter throw from the stick is epic.

[ozonehostile]

Nice work fellas! 

Love builds like this. 

All the best things were built over a weekend haha 

[Jonny81191]

Glad it's worked out with the gearchange, especially if it's shortened the throw!

[Dum-Dum]

Would you of had an easier time with that turbo if you'd just bolted it to the manifold and not made an adapter that made it about an inch lower?

[toseland]

3 stud to 4 stud, the clearance below isnt the issue, its left to right..

[zx_volcane]

awesome work!!

---

can't help think the exhaust system will be your next restriction mind

It was a busy weekend, i need a bigger workshops though

Exhaust shouldn't be too much of a restriction, look at zx volcane for example. 

mine is running a 3inch downpipe from turbo then 2.5 + a single unrestrictive back box (straight pipe with baffle) so not too dissimilar

pretty amazing the amount of work you got done in weekend, shows what you can do if you put your mind (hands) to it

[Poodle]

Thanks guys.

If we'd put the turbo much higher it was going to be touching the bulkhead. Wasn't ideal, but we're working on a better solution.

Tbh the exhaust could be bigger, but Toseland made it clear he wanted something that sounded entertaining and high gas velocity sounds good haha.

[Uberderv]

Pic 2 looks nice and cosy Impressive stuff lads, when will the maiden voyage be?

[Seb_Ryan]

Gotta be fair this sounded well earlier

[Uberderv]

How is this holding up? I would like to see how the turbo exhaust outlet is performing.

[Matt-Rallye]

How is this holding up?  I would like to see how the turbo exhaust outlet is performing.

Besides the (standard!!) clutch slipping slightly under heavy load, this thing was going damn well on sunday!

[205dtub]

Nice fab work, any more progress?

[Jonny81191]

This went on the rollers recently, I'll let Toseland post the results up but I beleive it's going well!

[bashbarnard]

Oohhh rr results so we can all take the piss and say how off they are because of xyz is wrong with the dyno

[Matt-Rallye]

Oohhh rr results so we can all take the piss and say how off they are because of xyz is wrong with the dyno

QFT

[bashbarnard]

Hows this going. every thing still holding up ok etc

[Sambarker]

Dyno figures?

[Matt-Rallye]

Yeah toseland.. RR figures!

[toseland]

http://306oc.co.uk/forum/showthread.php?...#pid567422 RR results in here!

Torque is low as ZX said, because of the ramp speed of the dyno (had a chat with the operator, HP will be correct but the torque will not be max, he estimates around 300ft/lb tho given the HP and diesel application.)


car still going strong.. starting to wear things out in addition to tyres now.

[toseland]

So, a little progress as the car is now lowered and stable

Visited the beam fairy, and purchased a shiney new '6 beam, lowered 40-50mm, new febi mounts all round and powerflex assisters fitted as they were cheap
   

Blistein B4s on the front with H+R 40mm lowering springs (lovely ride)  red came with it @ 60mm, too low for me on the HDi as they are/were 6 springs,

   

Also fitted some nice new lemforder balljoints to the front and these arms, with powerflex black polybushes front and back and the ride is precise and solid.






Still to do:

Relocate EGR and fit new gauge
Relocate Boost gauge to stalk type mount and remove the two gauge pillar pod.

STILL got to find an R70, and 1800bar sensor.