[project] Nothing To Do With 205's, But Behold!

[hman205 1]

done anything on the GT6 recently?

[M3Evo 0]

Lots of thinking, and very little working unfortunately.

 

Gonna get the new turbo system up and running and then move on to the GT6.

 

Had thought that subframes would be the best way to go, but probably the easiest way to make that work is to make a seperate chassis with the right wheelbase and track, remove the whole underside of the GT and plonk it on top.

[M3Evo 0]

Yip doo!

 

More progress this weekend:

 

The turbos mounted on the tacked together manifold:

 

 

 

 

 

The tacked fannymold in the car just to make sure the biggun fits:

 

 

 

Which it just about does. Think I might need some vents when I eventually get around to making a new bonnet: The standard lid does shut though so I might not bother with the venting:

 

 

 

 

 

And finally once I was happy that everything would fit, the process of seam welding could begin. The little copper pipe coming out is there to supply shield gas to the rear of the welds.

 

 

[mickie 3]

awesome, good work

[Mandic 0]

Very nice indeed!

 

You Mig welded all that right? Looks very good,

 

Cheers

 

Ziga

[M3Evo 0]

Cheers chaps

 

I TIG welded them this time, much nicer than MIG once you get the hang of it (not that I've got the hang yet but practice makes perfect )

[phatgti 0]

Welding looks very nice to me!

[M3Evo 0]

Bleeeeee!

 

The manifold's finished!

 

Just gotta leave it to settle for a couple of weeks and then take it to get skimmed.

 

Here's the finished article:

 

Some welds on the runners:

 

 

 

The T3 end of the mani:

 

 

 

The T25 sized flange showing a tiny bit of the baffling. For anyone who's interested, the HX27 doesn't bolt straight onto a T25 pattern flange as the Garret hole's a little bit too big. That's why there's a load of weld around the hole, I needed to make up filler pieces so the holes matched.

 

 

 

Here's the hwole thing from another angle:

 

 

 

And lastly, the welds I was most proud of....although that's not saying much

 

[Mandic 0]

Great effort!!!

 

Congrats,

 

Just one thing, why do You need to get it skimmed? You mean the mating surface?

 

Did You weld it on the head or at least had it bolted down or did You just weld it without any support? Cos if You had it bolted down and if it had bent then You shouldnt worry as it will bend correctly again when torqued to the head.

 

Cheers

 

Ziga

Edited July 16, 2007 by Mandic

[M3Evo 0]

I did have it bolted onto a spare head but it's still pulled a little bit.

 

Don't think it'd hurt to have it skimmed flat, and the flange for the small turbo has definately warped and, as I don't wanna use any gaskets for the turbos, I'm gonna need that skimming.

 

All good fun

 

Now, onto the computer side of things.....oh and building the new engine......and making the charge cooler, 48mm throttles and all the other bits and pieces

[Mandic 0]

Neverending story

 

Anyway, I just wanna point out that if You used head when welding, You shouldnt worry, at least that's what honda tech guys say, who do such things for a living. I'm saying this cos skimming cost some money and it can be saved. But then again, only with skimming You can be 100% sure it wont blow by.

 

Cheers

 

Ziga

[M3Evo 0]

Hmmm, piccies seem to have stopped working

 

Anyhoo, I've had a really good think about the control strategy of the system and I believe that I can control the two wastegates using the PWM controls (there are two tables using throttle position and rpm as their inputs) and then make a relatively simple extra PWM controller which just looks at the pressure between the turbos and opens the air divertor valve as a function of that pressure, so it's just a 2D thing rather than a 3D thing....gy.

 

Also, after seeking to make all this torque off idle, I'm now having thoughts of holding the little turbo's wastegate open at idle and progressively closing it as the throttle opens, only for it to open fully again when the large turbo's started doing it's bit. Might also be a good use of Emerald's multi-map thing as wet weather driving might be a real issue.

[cybernck 400 1 Cars]

i'll sort out the pics soon as i'm re-arranging the assorted pics to their seperate sub-albums .

[M3Evo 0]

Coolio, anyhoo here's some more

 

Piccies of the charge cooler I've been working on:

 

Nobody's allowed to laugh at my pitiful attempts at aluminium welding though:

 

Here's the secondary plenum where cold air gathers ready to be fed into the throttle bodies. There will be 6 outlet stubs welded on the more vertical face in the photo at some point.

 

 

Here's a closer-up of some poopy welding:

 

 

These are the water tanks which cooling water is fed to and from at either end of the core.

 

 

Here are most of the components which go to make up the cooler. The big black thing is the intercooler from a 2wd Sierra Cosworth with it's end tanks sawn off:

 

 

And the bits arranged as they'll eventually be welded up. The great big 3" pipe at the back of the photo will be cut down so that it lines through with the angle of the top and bottom plates. The pipe lives on the exhaust side and faces forward in the engine bay.

 

 

 

And lastly, here's a little pic of the PIC microcontroller kit which arrived the other day, computer nerd-dom awaits me!

 

[tom_m 0]

*dribbles*

[M3Evo 0]

Had a nice day of fabrication and welding today, working on the charge cooler.

 

Think it's coming together quite nicely now I'm vaguely getting the hang of TIG welding. Have adjusted the %EN setting a little bit to give better penetration and a flatter weld. Seems to be doing the trick

 

Here's what it'll look like....ish:

 

 

 

Same thing from a different angle:

 

 

 

And lastly some weldy welds. Just gotta get the hang of tacking things together. Always seem to end up with a great big blob of weld

 

[Mandic 0]

Good progress,

 

This chargecooler thingy is really impressive. On my T16 I rerouted the original system and relocated CC radiator from bedind the grill to infront of it. Water circulation is maintained by 27l/min pump and when engine is up to temp the CC is as cold as when I start the engine. Haven't measured IAT, but the difference can certainly be felt and it is not dropping during engine operation like before.

 

Regarding weld finish/end, I think this is normal, maybe not to such extent, but I think it is. Local welder over here does it also.

 

Cheers

 

Ziga

[M3Evo 0]

That's reassuring I think I paid extra attention to getting the top side welds to look as nice as possible.

 

Anyhoo, little bit more progress today:

 

been making a start on the throttle body manifolds.

 

Here's the template I made for the last set to score around:

 

 

 

The 8mm thick blanks ready for drilling and lots of filing:

 

 

 

The drilled blanks on the head. The front most one is shaped to clear the thermostat housing. Great for air flow like this

 

 

 

Anyway, once they fit, ya drills a couple of 20mm holes in them to give this and let you get a grrrreat big file in:

 

 

 

And after about 15 or 20 mins on each port, they look like this, all reasonably well matched and sloping at an angle to match the port:

 

 

 

Lastly, here the finished plates are with one of the 48mm throttles which is to go on the engine winkeye

 

[base-1 17]

Aaaaawwwesome

[tom_m 0]

*dribbles more*

[greig 0]

niiiiiiiiiiiiice!

[M3Evo 0]

Little bit more progress after the belt broke on the lathe last weekend leaving me machineless All sorted now though

 

SO! Here's some component parts of the inlet manifolds and one which is about half done and has a throttle bolted to it.

 

 

 

The half done mani from the side showing the angle of attack the runner has into the port. Believe it or not, the bottom of the runner lines up exactly with the bottom of the port.

 

 

 

Here's a look down the throttle:

 

 

 

And one showing the transition from runner to head flange. The large hole will be filled by a welded plate (the thing which is kinda shield shaped in the first piccy) and the injector bosses will be welded to those plates. Advice when I was at Emerald was to move the injectors away from the head to get better mixing.

 

 

 

For anyone wondering why the runners are so long, it's because of that pesky thermostat housing which is very close to cyl1's port. Make the runners about 120mm long though and you've got all the room you could want

 

Did a trial fit of the E36 front hubs today. Looks like all that's needed is to modify the rear crud guard a bit and then make up a very simple sleeve to take the diameter of the spigot out. The E30 nut looks big enough and goes on 5 1/2 turns which is more than enough in my opinion

 

Think I'm going to need about a 3mm spacer behind the E46 330Ci brake discs to get enough clearance for the track rod ends but that's no great shakes. What does remain to be seen is whether the offset of the front wheels will need altering as there's about 13mm from the inner edge of the rim to the strut and, on an 8J rim I think I need the wheels as far into the arches as possible. Should just be a case of making up a set of spacers for the wheels so that the rim sits further in, will give me that nice staggered offset look too

 

 

Finally, on a more aesthetic note, I had another go at dismantling the wheels today. I tried standing in them, levering at them and was about to resort to chemicals but thought I'd give a hammer a go. Found a nice rubber headed hammer and gave the back of the spokes a twat and, after several knocks the centre dropped out

 

 

 

 

I'm really torn now between making more manifolds for the throttles tomorrow or whether to attack the rim sections with the polish!

 

 

Oh yeah, and as an aside, I'm getting a Ford style heated windscreen for the car too. How cools is that ?!!

[rapidmi 4]

minted lovley work m8 keep the pics coming

[M3Evo 0]

So, this weekends spoils are.....the dump valve! Just needs a spring and a pipe connection in the top and it's done!

 

Here's the component parts:

 

 

 

 

And the assembled valve:

 

 

 

Looks a lot shinier in real life

[M3Evo 0]

Been burying my head a bit with the eletronics but will need to look at them again soon I think, I'm just not getting it

 

Anyway, not had an amasingly productive weekend, but have managed to close off one of the inlet manifolds and get another to about 50% completion before running out of gas. Couldn't figure out why the weld just would take on the last one until I flicked the gauge on the bottle which made it drop to zero

 

So, here's the most complete manifold which just needs injector bosses and fuel rail ties welding on