New winter new turbo build
12-04-2009, 08:23 PM
#143
Well, it's been a while. Unfortunletly we had a passing in the family, so work in the garage had halted for a bit.
So now things are getting back on track. I did some work this evening and hope to complete the first one of kit this weekend. The pumps have finally arrived:
I built a small oil catch reservoir with a vent, this will allow the oil to drain once the car has been turned off. Many people rely on a 12V selonoid mounted just before the turbo on the oil supply line. I see selonoids at work fail all the time, so that was a no no.
I also redid a section of the IC piping. It is VERY tight here, and I managed to get a bit more clearance. It is about 3/8 of an inch, and will be fine. I was very close to saying f..it and going with 2.5" tubing (and I think it would be plenty for 500whp) but will stick with the 2.75 (about 17% increase in max flow over 2.5"). To the pipe through there you have to turn the steering over so the bolt going the other way..
This is what I mean:
So now things are getting back on track. I did some work this evening and hope to complete the first one of kit this weekend. The pumps have finally arrived:
I built a small oil catch reservoir with a vent, this will allow the oil to drain once the car has been turned off. Many people rely on a 12V selonoid mounted just before the turbo on the oil supply line. I see selonoids at work fail all the time, so that was a no no.
I also redid a section of the IC piping. It is VERY tight here, and I managed to get a bit more clearance. It is about 3/8 of an inch, and will be fine. I was very close to saying f..it and going with 2.5" tubing (and I think it would be plenty for 500whp) but will stick with the 2.75 (about 17% increase in max flow over 2.5"). To the pipe through there you have to turn the steering over so the bolt going the other way..
This is what I mean:
12-04-2009, 08:36 PM
#144
very nice.
have not seem a return sump/pump with an oil solenoid though to stop flow.
on a VQ anyhow. not sure how your system is different than any other VQ setup. STS, SP and SFR never used a solenoid. The vent is a nice touch so you dont create a vacuum.
have not seem a return sump/pump with an oil solenoid though to stop flow.
on a VQ anyhow. not sure how your system is different than any other VQ setup. STS, SP and SFR never used a solenoid. The vent is a nice touch so you dont create a vacuum.
Last edited by str8dum1; 12-04-2009 at 08:37 PM.
12-13-2009, 03:57 PM
#145
A bit of an update, I am finally getting back on track here and should be shipping the "one of" kit out next week. The weather here has really gone down the crapper, and we are looking at -30's and -40's at times.
Anyway, here are a couple of pictures:
DP:
I had to find a way to get a hanger in there, otherwise all the weight would be on the headers. This would not have been good, but in the end it all woked out:
I am not sure how this compares to other ST kits out there, but that is not much piping at all. The IC piping you see below is from turbo to intercooler, from intercooler to TB is another 3ft. I am very happy with the exhaust side, not one 90 degree bend anywehre. Should be good for flow.
I have to weld up the IC piping tommorow night and make a bracket for the scavenge pump. Other than that, it is complete. I ordered enough piping, both IC and exhaust to get four kits made during the holidays.
Anyway, here are a couple of pictures:
DP:
I had to find a way to get a hanger in there, otherwise all the weight would be on the headers. This would not have been good, but in the end it all woked out:
I am not sure how this compares to other ST kits out there, but that is not much piping at all. The IC piping you see below is from turbo to intercooler, from intercooler to TB is another 3ft. I am very happy with the exhaust side, not one 90 degree bend anywehre. Should be good for flow.
I have to weld up the IC piping tommorow night and make a bracket for the scavenge pump. Other than that, it is complete. I ordered enough piping, both IC and exhaust to get four kits made during the holidays.
Last edited by BoostedProbe; 12-13-2009 at 04:01 PM.
12-14-2009, 06:47 PM
#148
Any time you tig weld tubing (except aluminum) you "should" back purge. I can weld tubing well enough that I don't need to back purge, but do it anyway. The key to it is temperature and speed at which you move. It is not that hard once you have enough practice.
It is not 304 stainless. When 304 stainless is subjected to frequent heat cycles it tends to crack at the welds. Well, not right at the weld, it is usually right befor or right after the beed. I have seen this many times, as it is much harder than other metals and has zero resistance to flex.
The stuff that I use is 409 stainless, this is the proper grade for exhausts as it is softer and will endure heat cycles much better than 304 grade. I am a firm believer in doing things right, or don't do them at all.
Back purge was used for all except the end welds. It is hard to seal the ends (to prevent argon from excaping) with something that will withstand the heat. The sugaring was minimal (at the ends) and because it is at the end of the pipe it gets removed and polished. No sugaring on the inside anywhere, nice and smooth. You can see the pictures below, there is a weld about 5 inches from the header flange. Not cleaned and no sugaring:
Driver side:
Passenger side:
Turbo flange, sorry for the blury picture. Not the greatest camer for close up shots, but you get the idea, all nice and smooth:
I have ordered enough IC piping and 409 stainless piping to make 4 kits during the holiday. This is really the hardest part. The reservoirs for the turbos, IC mounting brackets, scavenge pump brackets...and things like that are already done. I have 6 intercoolers here already and 4 scavenge pumps. All I really need to get are the BOV's, W/G's and turbos. Then it's just a matter of puting all the parts in to a package and shipping.
As for per order kits, I can do those too. One may consider a full 4" downpipe/exhaust for an example. It is very doable, do to the location advantages.
It's -35 degrees outside, what good time to make turbo kits.
Last edited by BoostedProbe; 12-14-2009 at 07:05 PM.
12-14-2009, 07:41 PM
#151
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BP you need any graphics design work or logo development, websites, marketing ideas.. etc, hit me up. I do that as a hobby to keep me busy during slow months.
12-19-2009, 09:02 AM
#157
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12-20-2009, 09:48 PM
#160
Bit of an update. I am currently working on install instructions. It will be very easy to install, I think the hardest thing will be removing the bumper. If you want to call that hard.
Couple of shots with the wastegate up there:
I am labling all the IC piping to make the install as easy as possible:
Couple of shots with the wastegate up there:
I am labling all the IC piping to make the install as easy as possible: