Danm54 Posted January 30, 2017 Author Share Posted January 30, 2017 Well today was build day but it didn't start until mid afternoon! Got the head on and then spent forever dialing the cams in. The spacer under the barrels threw things out a bit and it took a bit of working out to get the cam sprockets right so the adjustment range worked ok. Got the exhaust cam at 110.5 degrees which is spot on but the intake cam keeps falling 1-2 degrees out either way. Left it for tonight and I'll re-check the degree wheel and exhaust cam tomorrow then have another go at the intake cam. Quote Link to comment
Danm54 Posted February 1, 2017 Author Share Posted February 1, 2017 Cams dialed in finally, the degree wheel had moved a touch so reset it and double checked it all once I'd finished. Intake lobe centre is 108.25 Exhaust lobe centre is 110.5 Got a few other bits bolted on but hit a problem with the plenum, the o-ring seals are made of cord and have shrunk slightly so there's now a gap. Measured up and ordered some new ones, hopefully they'll fit. Can get the headers back on though and finish them off. 1 Quote Link to comment
Danm54 Posted February 2, 2017 Author Share Posted February 2, 2017 O-rings fit a treat, not sure if the grooves were machined to fit a 42.5mm o-ring but they're a perfect fit. 2 Quote Link to comment
Danm54 Posted February 3, 2017 Author Share Posted February 3, 2017 Im no photography expert but the shed lighting as all wrong at this angle! Tacked it together now and need to sort out the wastegate connection. 4 Quote Link to comment
Danm54 Posted February 8, 2017 Author Share Posted February 8, 2017 Started on the wastegate, need to trim the length a little but I'll wait until the new gate is here first. Will probably get it welded to the headers first then I can finish the rest off. 2 Quote Link to comment
Tombola Posted February 9, 2017 Share Posted February 9, 2017 Nice work mate, did you have a job fitting your headers after you welded them up? Quote Link to comment
Danm54 Posted February 9, 2017 Author Share Posted February 9, 2017 21 minutes ago, Tombola said: Nice work mate, did you have a job fitting your headers after you welded them up? They were pretty much spot on but I was careful on the order I welded it in and didn't trim the last bits until the rest was welded. I also had them bolted to a spare head during welding. Plus they're reasonably easy to tweak a touch if needed. 1 Quote Link to comment
Tombola Posted February 10, 2017 Share Posted February 10, 2017 Was you welding them up as you went along? I tacked nearly all mine and welded the tubes I wouldn't of been able to get to, my outer runners was the worst affected by distortion, but like you say easily tweaked with a bit more heat. Did you purge the inside? Quote Link to comment
Danm54 Posted February 11, 2017 Author Share Posted February 11, 2017 (edited) Didn't purge inside no, should have done I suppose but I cleaned up any bits on the inside as I went along. I welded the outer 2 fully first then set up and fully welded the inner 2 but I left one joint on each just above the collector. I trimmed these to fit last then bolted it all to the head and welded the last joint. Tacked it in a couple of places around the tube the alternated the welding leaving it to cool between welds so it didn't get too hot. Well fitting tube doesn't seem to warp much but anything with gaps pulls in and long runs on collectors seem to warp too. I'm no expert though! Edited February 11, 2017 by Danm54 1 Quote Link to comment
Leblowski Posted February 11, 2017 Share Posted February 11, 2017 Always use purging gas welding headers its more expensive when you turbo gets destroyed by welding debree. always weld headers in a jig or old head i learned a lot making headers during the last years Quote Link to comment
wombat258 Posted February 12, 2017 Share Posted February 12, 2017 I use Sola welding flux on the inside of the stainless tubes when I TIG, and it gives a nice finish on the inside of the tubes without purge. I weld the headers on an old head. Tight fitting prepped joints anjd generous tacks help avoid distortion. Quote Link to comment
Tombola Posted February 12, 2017 Share Posted February 12, 2017 Solar flux? Sounds like hard work brushing that on every joint Quote Link to comment
wombat258 Posted February 12, 2017 Share Posted February 12, 2017 Only a fraction of the time that you should spend on prepping the joints properly, or making fixtures to properly purge the inside of the pipes. Its really not that hard, and it avoids those nasty dags hanging inside your exhaust. Quote Link to comment
Danm54 Posted February 25, 2017 Author Share Posted February 25, 2017 V-band clamp is finished, just need to decided on a wastegate, going Tial but think I might go for the v-band option for the extra few quid. 6 Quote Link to comment
Fula28 Posted February 27, 2017 Share Posted February 27, 2017 V-bands are great quick easy to remove and line up too! Use them a lot at work speedy connections rule. Quote Link to comment
Gixer1460 Posted February 27, 2017 Share Posted February 27, 2017 Great if you're swopping or constantly off'ing and on'ing but how many times do you need to remove a wastegate quickly? Quote Link to comment
Danm54 Posted February 27, 2017 Author Share Posted February 27, 2017 I could stick with the flange type but its only £30 extra for the newer v-band type. Make changing springs piss easy and avoids broken gaskets. Quote Link to comment
Leblowski Posted February 27, 2017 Share Posted February 27, 2017 I've got bov and wastegate vband although you dont change then much its really nice and looks good so for a few extra bucks buy vband if you can Quote Link to comment
Danm54 Posted March 23, 2017 Author Share Posted March 23, 2017 This arrived yesterday Sadly the 38mm wastegate has a 44mm inlet flange so fitting was delayed. Got a mate to make a bush last night so fitting will begin later. Quote Link to comment
Danm54 Posted March 23, 2017 Author Share Posted March 23, 2017 Well its in position and the outlet is tacked but I wasn't feeling the love for tig welding so I'm going to wait and weld it up once I've cleared some bench space. 6 Quote Link to comment
Danm54 Posted March 31, 2017 Author Share Posted March 31, 2017 All welded up and fitted, new filter and some fresh oil in too, spun it over to get some oil around and make sure I had oil pressure, all good. Fitted the rad and filled with coolant, tank on then needed fuel. Quick run out and for a few litres, primed the fuel lines the hit the go button, didn't go first time but only needed a sniff the second time and it fired right up. Idled nicely, revved cleanly, steady .85 lambda and coolant temps only reached 70c after about 5 mins running. Toyed with the idea of putting the seat on and going out tomorrow but think I'll put it in for a dyno day first. Play safe and all that. 5 Quote Link to comment
Danm54 Posted April 30, 2017 Author Share Posted April 30, 2017 (edited) Things have been full on the last few weeks but managed the odd hour here and there, pretty much ready for some dyno time but I did take it down the road to make sure clutch etc still worked. Got this weird breathing noise after shut off thats concerning me slightly though. I remember hearing it at the last dyno session and it may have made it before but I think its only been since the turbo was rebuilt. Thoughts? I'll try and upload a vid. Edited April 30, 2017 by Danm54 Quote Link to comment
Gixer1460 Posted April 30, 2017 Share Posted April 30, 2017 'Shut off' as in engine shut off or as in shut throttle? If the latter it is normal if a BOV is fitted (and it should be)...... it releases excess compressed air. If the former I've got no idea - maybe its possessed and needs to see a priest rather than a meknik LOL! Quote Link to comment
Danm54 Posted April 30, 2017 Author Share Posted April 30, 2017 Shut off as in turn it off. Could be possessed I suppose, would explain a few things! Quote Link to comment
Tombola Posted April 30, 2017 Share Posted April 30, 2017 Breathers on the engine alright? Quote Link to comment
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.