The wastegate is real tight to the subframe, about a finger width in-between the w/g and the subframe. I'd have to notch a piece out of the subframe to make it work..a bit more work than I was hoping for.
Tracking info shows my Braille battery and stuff I need for install should be here on Thursday, along with my DEI Titanium wrap and some other goodies, so I can finalize the install of the turbo system.
My new car!
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chickenwafer
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Got a lot of work done on the car today. Started at 9AM with installing the turbo system after I wrapped the manifold in DEI's new Titanium head wrap. I thought this job would take about 1-2 hours. WRONG WRONG WROOOOOONG! Oh, the misery. I finished installing the turbo at about 3PM with a 45 minute lunch break, haha.
First I got the manifold bolted in with my new exhaust gaskets, pretty easy. Then the fun part. My turbo doesn't fit on the manifold (it hits the LIM) so the previous owner included a T4 divided manifold flange to use as a spacer in-between the turbine housing the manifold.
So it was real interesting trying to line up the heavy turbo, a gasket, the T4 spacer flange, and another gasket. Then, due to the location of the bolt locations on the turbine housing flange, the bolts were a major PITA to get to.
After struggling with getting the turbo on the manifold for around 2 hours, it was finally in. Then came time for the oil drain...another major bitch, just no access. I took off the compressor housing to gain more access, but it didn't help much. I finally found out that the CHRA is clocked about 15* when with the AN fittings I have it needs to be straight up and down. So I attempted to loosen the bolts for the turbine housing to I could clock the CHRA, but of course, there was one bolt I couldn't access.
And I wasn't about to remove the turbo again after the debacle of putting it on...so I made a new oil drain hose and bent my 90* -10AN fitting and made it work. It isn't pretty, but it works (hopefully).
I then had to shorten oil feed hose I had previously made and got that installed. Lastly, I tried to install the turbo blanket on the turbine housing, but the housing is about a sheet of thick paper from the LIM, so I have NO idea how I'm going to install that.
As I was wrapping stuff up under the hood, UPS dropped off my Braille B2015 battery and aluminum mounting kit, along with some crimp connectors, so installed the battery, breaker, and Battery Tender JR in the spare tire well. The car has powwa!!
Finally, onto the pics!!
Battery:
Engine bay (it's a little messy):
First I got the manifold bolted in with my new exhaust gaskets, pretty easy. Then the fun part. My turbo doesn't fit on the manifold (it hits the LIM) so the previous owner included a T4 divided manifold flange to use as a spacer in-between the turbine housing the manifold.
So it was real interesting trying to line up the heavy turbo, a gasket, the T4 spacer flange, and another gasket. Then, due to the location of the bolt locations on the turbine housing flange, the bolts were a major PITA to get to.
After struggling with getting the turbo on the manifold for around 2 hours, it was finally in. Then came time for the oil drain...another major bitch, just no access. I took off the compressor housing to gain more access, but it didn't help much. I finally found out that the CHRA is clocked about 15* when with the AN fittings I have it needs to be straight up and down. So I attempted to loosen the bolts for the turbine housing to I could clock the CHRA, but of course, there was one bolt I couldn't access.
And I wasn't about to remove the turbo again after the debacle of putting it on...so I made a new oil drain hose and bent my 90* -10AN fitting and made it work. It isn't pretty, but it works (hopefully).
I then had to shorten oil feed hose I had previously made and got that installed. Lastly, I tried to install the turbo blanket on the turbine housing, but the housing is about a sheet of thick paper from the LIM, so I have NO idea how I'm going to install that.
As I was wrapping stuff up under the hood, UPS dropped off my Braille B2015 battery and aluminum mounting kit, along with some crimp connectors, so installed the battery, breaker, and Battery Tender JR in the spare tire well. The car has powwa!!
Finally, onto the pics!!
Battery:
Engine bay (it's a little messy):
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speedjunkie
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chickenwafer
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speedjunkie wrote:Why don't you just take the turbo off to install the blanket?
LOL jk.
I like that battery setup though. Looks good there. Makes me want to change mine again lol. Where is the battery tender jr?
Haha, that turbo isn't coming off unless it HAS to. What a pain. I think it might be easier to take the turbo off with the manifold (so turbo and manifold assembly together as one), but I would surely need another person to help. It's just an odd angle and a lot of weight down low.
Getting it out would be easy enough by myself, albeit not graceful, but getting it back in with the exhaust gaskets and all would be a nightmare by myself haha, especially since I removed the studs and used bolts now. The studs are a pain remove things but SOOOO much easier to install them, whereas bolts are so much easier to remove items for clearance but SOOO much more difficult to install and line stuff up.
The battery is pretty cool. I made a cardboard mock unit you can have it you need it to figure out placement. It weights 15lbs and it's a dry cell AGM battery so it can be mounted in any orientation. Can deliver up to 1067 pulse cranking amps so I think it should do the trick.
The Battery Tender is installed, but it's just the leads that permanently mount to the battery, on the other side of the leads is a quick-disconnect plug.
VRx8 wrote:Looks good, how are you planning on routing you catch can? I'm planning on welding a 6an bung to my existing filler neck and running a breather tank
I waiting on my RE-Speed aluminum filler neck that has a -10AN male fitting that will go to my JEGS aluminum breather tank with two -10AN fittings, then out of the catch tank to a special fitting on the rear iron oil drain port (normally plugged off for single turbo).
So it's all -10AN fittings (the size is key, -6AN is too small I think) from the oil filler neck to the catch can, from the other side of the catch can to the rear oil drain.
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chickenwafer
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Mailed off the injectors to Witch Hunter today, so I should (hopefully) have them back by next weekend or possibly sometime early next week. That and the oil filler neck are the last pieces to the puzzle.
I finished the oil system by installing the lines for the oil cooler to the thermostat, finally. I'm not thrilled with the mount on the oil cooler, it provides literally NO clearance between the fitting and the frame of the car. I will see if I can make a better one in the time being.
Got my dump pipe for the wastegate welded, but now it sits right where the downpipe passes through! No big deal, I just angle the dump pipe straight down and cut it at an angle. It's gonna be LOUD haha.
Downpipe is kind of a bitch thanks to the 2-bolt flange design. The inner bolt is basically impossible to get to, it's about 1-2 inches from the LIM so there isn't enough room to stick my hand in-between the LIM and downpipe. I might have to tighten it from the bottom of the car, but I'm not sure how. Ugggg. I wish the turbo was v-band! I might get an adapter like this:
http://www.atpturbo.com/mm5/merchant.mvc?Screen=PROD&Store_Code=tp&Product_Code=ATP-FLS-114&Category_Code=FLG
I also found a stainless steel heat shield that bolts to the turbine CHRA bolt from ATP I can run in lieu of the turbo blanket:
http://www.atpturbo.com/mm5/merchant.mvc?Screen=PROD&Store_Code=tp&Product_Code=ATP-ACS-022&Category_Code=
I know it won't be as effective, but it should be better than nothing.
I also found out -6AN hose is tight as HELL on the 3/8" nipples for the cooling system! It was a major bitch to get the hose over the hose barb, and even after lubing the barb liberally with Earls assembly lube and flaring the hose open as much as possible, it still took me a half hour to get the hose just half way up the barb. I put a clamp on it good and tight, hopefully it holds.
Lastly, those hose cutters I got from JEGS (basically glorified bolt cutters) for cutting the AN hose have dulled to hell now and don't cut the hose worth a shit anymore. They cut about 90% of the hose and leave the rest hanging by the stainless threads, which it won't cut. I've ruined a bunch of hose now because of this. I moved to cutting with my trusty electric angle grinder, which powers thru the hose without issue, but leaves a lot of dust inside the hose so I have to be sure to clean the hose out before assembly.
I finished the oil system by installing the lines for the oil cooler to the thermostat, finally. I'm not thrilled with the mount on the oil cooler, it provides literally NO clearance between the fitting and the frame of the car. I will see if I can make a better one in the time being.
Got my dump pipe for the wastegate welded, but now it sits right where the downpipe passes through! No big deal, I just angle the dump pipe straight down and cut it at an angle. It's gonna be LOUD haha.
Downpipe is kind of a bitch thanks to the 2-bolt flange design. The inner bolt is basically impossible to get to, it's about 1-2 inches from the LIM so there isn't enough room to stick my hand in-between the LIM and downpipe. I might have to tighten it from the bottom of the car, but I'm not sure how. Ugggg. I wish the turbo was v-band! I might get an adapter like this:
http://www.atpturbo.com/mm5/merchant.mvc?Screen=PROD&Store_Code=tp&Product_Code=ATP-FLS-114&Category_Code=FLG
I also found a stainless steel heat shield that bolts to the turbine CHRA bolt from ATP I can run in lieu of the turbo blanket:
http://www.atpturbo.com/mm5/merchant.mvc?Screen=PROD&Store_Code=tp&Product_Code=ATP-ACS-022&Category_Code=
I know it won't be as effective, but it should be better than nothing.
I also found out -6AN hose is tight as HELL on the 3/8" nipples for the cooling system! It was a major bitch to get the hose over the hose barb, and even after lubing the barb liberally with Earls assembly lube and flaring the hose open as much as possible, it still took me a half hour to get the hose just half way up the barb. I put a clamp on it good and tight, hopefully it holds.
Lastly, those hose cutters I got from JEGS (basically glorified bolt cutters) for cutting the AN hose have dulled to hell now and don't cut the hose worth a shit anymore. They cut about 90% of the hose and leave the rest hanging by the stainless threads, which it won't cut. I've ruined a bunch of hose now because of this. I moved to cutting with my trusty electric angle grinder, which powers thru the hose without issue, but leaves a lot of dust inside the hose so I have to be sure to clean the hose out before assembly.
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chickenwafer
- Posts: 2515
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Thanks Matt! Hopefully I get my injectors back soon so she will be firing up!
I also found out RE-Speed got their parts that were on back order yesterday, so hopefully they're making my oil filler neck and sending it out ASAP. I think I'm owed overnight delivery or something, I mean, it's only been A MONTH since I ordered it...
Just did some little stuff with the car today...modified one of the oil cooler brackets since I didn't like how it was hitting the fitting. Now it clears fine so I'm much happier with it, although I still need to test fit the bumper. I'm also not thrilled with how the undertray fits, so I think I'm going to scrap it for now and get a custom aluminum or carbon fiber one made down the road.
I also hacked up a 2.75" aluminum pipe for the charge pipe from the turbo to the intercooler. It's super short, I'm thrilled with how short the charge piping is with the v-mount setup. Anything I can do to help the spool haha. I am still pretty concerned about the clearance between the turbine housing the LIM...it's just sooo tight. I used my feeler gauges and I think it's roughly 0.065" of clearance haha. I'm just worried when the turbine housing heats up and expands it will contact the LIM. There really isn't anything I can short of getting my manifold modified...it's kind of silly, really, because if the turbo was just 1 inch moved forward, it would have all kinds of clearance...odd.
I also found out RE-Speed got their parts that were on back order yesterday, so hopefully they're making my oil filler neck and sending it out ASAP. I think I'm owed overnight delivery or something, I mean, it's only been A MONTH since I ordered it...
Just did some little stuff with the car today...modified one of the oil cooler brackets since I didn't like how it was hitting the fitting. Now it clears fine so I'm much happier with it, although I still need to test fit the bumper. I'm also not thrilled with how the undertray fits, so I think I'm going to scrap it for now and get a custom aluminum or carbon fiber one made down the road.
I also hacked up a 2.75" aluminum pipe for the charge pipe from the turbo to the intercooler. It's super short, I'm thrilled with how short the charge piping is with the v-mount setup. Anything I can do to help the spool haha. I am still pretty concerned about the clearance between the turbine housing the LIM...it's just sooo tight. I used my feeler gauges and I think it's roughly 0.065" of clearance haha. I'm just worried when the turbine housing heats up and expands it will contact the LIM. There really isn't anything I can short of getting my manifold modified...it's kind of silly, really, because if the turbo was just 1 inch moved forward, it would have all kinds of clearance...odd.
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speedjunkie
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chickenwafer
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speedjunkie
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chickenwafer
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Yeah, it's super close. It looks closer in the pictures, though.
I found a head shield from ATP that's stainless and bolts to the turbo, so I'm going to run that. I also ordered the remaining couplers I need to finish up the build.
Matt came by and helped fit the downpipe. It actually fits great! I was shocked, when I had previously attempted to fit it myself I thought it was too long for my midpipe, but turns out I didn't have it lined up right. So I'm going to get my WB02 sensor bung welded in tomorrow and then heat wrap it and install it tomorrow night hopefully.
I found a head shield from ATP that's stainless and bolts to the turbo, so I'm going to run that. I also ordered the remaining couplers I need to finish up the build.
Matt came by and helped fit the downpipe. It actually fits great! I was shocked, when I had previously attempted to fit it myself I thought it was too long for my midpipe, but turns out I didn't have it lined up right. So I'm going to get my WB02 sensor bung welded in tomorrow and then heat wrap it and install it tomorrow night hopefully.
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chickenwafer
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So RE-Speed is being a dick...I used the tracking number they provided me with for their materials (the reason my oil filler neck is MIA) and it shows it was delivered on March 19th.
So on the 21st I fire off an email asking if they have made my oil neck yet seeing has they have the materials to do so for 2 days, and I also asked for expedited shipping since it's been over a month since I paid and ordered my neck. I got no reply.
So this morning I sent another email asking if they have shipped my neck yet and again, if they could expedite the shipping. It's been 31 days, today, since I paid in full for the oil filler neck. Still no reply.
I have 45 days to file a dispute with PayPal, so I figure I will wait until Monday and then finally threaten a PayPal dispute and see if that gets me an answer. I'm also posting in their vendor section on 7club. This is getting stupid.
So on the 21st I fire off an email asking if they have made my oil neck yet seeing has they have the materials to do so for 2 days, and I also asked for expedited shipping since it's been over a month since I paid and ordered my neck. I got no reply.
So this morning I sent another email asking if they have shipped my neck yet and again, if they could expedite the shipping. It's been 31 days, today, since I paid in full for the oil filler neck. Still no reply.
I have 45 days to file a dispute with PayPal, so I figure I will wait until Monday and then finally threaten a PayPal dispute and see if that gets me an answer. I'm also posting in their vendor section on 7club. This is getting stupid.
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speedjunkie
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chickenwafer
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Well I went to post something on 7club but I found out that this seems more or less, normal for them.
It's just really frustrating because once I get my injectors back from Witch Hunter the only thing preventing me from firing this pig up is the stupid oil filler neck. I guess I could add oil with a funnel but I don't have any way of connecting my catch can system and I really, really don't want to make a mess of my engine bay if oil happens to puke out the filler hole, which seems likely.
I'm wondering if I could just get a refund and have my fabricator/welder here in Loveland make the neck for me. It would just be difficult to fab without having something to replicate it from.
Edit: just a small update and didn't feel like it needed a whole new post so I'm adding it to this one. Got the 02 sensor bung for my WB02 welded in the downpipe and picked up some black Thermotech heat wrap and some misc vacuum caps at AutoZone.
I had to plug two more coolant passages since I'm not able to run water cooling to the wastegate for the time being, so I got some good rubber caps and pumped some grey RTV silicone in them and put them on the nipples using a hose clamp to secure them. The RTV helps by creating a better seal and also prevents the rubber cap from over heating and cracking as much and leaking.
I also modified the dump pipe for the w/g so it could clear the downpipe. It will be getting heat wrapped shortly.
Plans for today are to get the downpipe and dump pipe heat wrapped, install the dump pipe and then the downpipe, install the AEM WB02 sensor and hook it up. Also now that the coolant system is finally wrapped up I can pressure test it as well.
Finally, I ordered a stubby K&N air filter off eBay, it has a 4" inlet (for the turbo) but it's only 3.5" long so it should do the trick, since I have roughly 4.5"-5" in-between the compressor inlet of my turbo and the v-mount. I tried another filter but it just wouldn't work. I was originally actually planning on running filter-less with maybe a velocity stack/funnel thing, but I read a lot of stuff online that it's really bad for the compressors blades- they can "gum up" from the dirt and dust it chops up, leading to poor compressor performance and eventually, compressor failure. I decided it wasn't worth it for a $30 filter so one is on the way.
It's just really frustrating because once I get my injectors back from Witch Hunter the only thing preventing me from firing this pig up is the stupid oil filler neck. I guess I could add oil with a funnel but I don't have any way of connecting my catch can system and I really, really don't want to make a mess of my engine bay if oil happens to puke out the filler hole, which seems likely.
I'm wondering if I could just get a refund and have my fabricator/welder here in Loveland make the neck for me. It would just be difficult to fab without having something to replicate it from.
Edit: just a small update and didn't feel like it needed a whole new post so I'm adding it to this one. Got the 02 sensor bung for my WB02 welded in the downpipe and picked up some black Thermotech heat wrap and some misc vacuum caps at AutoZone.
I had to plug two more coolant passages since I'm not able to run water cooling to the wastegate for the time being, so I got some good rubber caps and pumped some grey RTV silicone in them and put them on the nipples using a hose clamp to secure them. The RTV helps by creating a better seal and also prevents the rubber cap from over heating and cracking as much and leaking.
I also modified the dump pipe for the w/g so it could clear the downpipe. It will be getting heat wrapped shortly.
Plans for today are to get the downpipe and dump pipe heat wrapped, install the dump pipe and then the downpipe, install the AEM WB02 sensor and hook it up. Also now that the coolant system is finally wrapped up I can pressure test it as well.
Finally, I ordered a stubby K&N air filter off eBay, it has a 4" inlet (for the turbo) but it's only 3.5" long so it should do the trick, since I have roughly 4.5"-5" in-between the compressor inlet of my turbo and the v-mount. I tried another filter but it just wouldn't work. I was originally actually planning on running filter-less with maybe a velocity stack/funnel thing, but I read a lot of stuff online that it's really bad for the compressors blades- they can "gum up" from the dirt and dust it chops up, leading to poor compressor performance and eventually, compressor failure. I decided it wasn't worth it for a $30 filter so one is on the way.
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