ghetto turbo build page 3

[CMF_frank2]

following on from page 2
https://micra.org.uk/cmf/message/75745

some cut-away pics of the piston options
CG13, CGA3 (the current ones), corsa and the LPG CG13 ones that i det,ed on week 1 page 1

 

[CMF_climberjoel]

keep up the good work Frank, three pages of pure awesome I say! Hows the new rear suspension going?

 

[CMF_frank2]

climberjoel WROTE:

"keep up the good work Frank, three pages of pure awesome I say! Hows the new rear suspension going?

cheers joel the axle project is gathering dust atm i,m afraid (tinkering with this white car is far more appealing )
the superior spool-up and response of the bigger exh system means that we,ve refitted the 1/2 bar wastegate setup, those skinny little CGA3 top ringlands wont sustain much more than that i guess.
but it just goes to show how much the pressure difference before and after the exh turbine effects boost and spool eh (if you have 20 psi of exhaust pressure in the manifold, and 15 psi of backpressure in the exh system, then the best you will ever get from the compressor is a laggy 5 psi eh)

 

[CMF_frank2]

axle in at last (all very much to plan...........strangely)
you can see the effect of the stiff setup now, the nearside shock is only half extended but the antiroll design of the axle wont let it droop

 

[CMF_frank2]

and we,re currently running a more daily d friendly GT1549, from an N16 2.2D
with a more remote mounted TD05 wastegate, and screamer pipe the arrow shows where the original W/G was (right where the exh gasses are concentrated to a fast flowing jet)

 

[CMF_frank2]

in situ, showing the diesel exhaust recirculating valve (to avoid the compressor surge)

 

[CMF_Glenj]

Nice, will drop the grasser off weekend frank for a overhaul

 

[CMF_frank2]

Glenj WROTE:

"Nice, will drop the grasser off weekend frank for a overhaul

sounds like you have yours sorted anyway mate
the GT1549 is running mint, but the TD05 needs less backpressure, so we,re doin a s/s 60mm system atm
1 long cherrybomb jobbie to fill the transmission tunnel ready for welding

 

[CMF_frank2]

pic 2

 

[CMF_k11_facelift]

That looks nice mate, and much much cheaper than the shop bought equivelent too. Are you trying to quieten the side exit exhaust? Only thing that quietened mine was making a chamber type silencer, using the stock backbox, which made it rear exit and about 8KGs heavier.. and it still ended up being quite loud.

 

[CMF_frank2]

k11_facelift WROTE:
Are you trying to quieten the side exit exhaust?

yes matt, its not much louder than stock atm, and i,m trying to keep it that way
made a start on the 63mm s/s downpipe today

 

[CMF_frank2]

forgot the pic lol

 

[CMF_frank2]

downpipe, and the 60mm side exit 4 ft cherrybomb fitted now so we,re spooling to 9psi @ 2.5k rpm in 5th gear now (the white portion of the gauge is 0 to 10 psi
and hooned it round our track again today the boost gauge was hitting about 13 psi @ 9 and 13 secs eh
untouched 5 months now on that stock engine with the ebay H/G......nistune and fusion basemap ftmofow

 

[CMF_frank2]

another couple of vids


you can see the w/g actuating rod reacting to my throttle movements eh
and this was with a small barbed fitting welded to the downpipe, and connected to the boost gauge for an exhaust system backpressure test

 

[CMF_frank2]

could only manage a 15.3 yesterday

and having to run N/A this week for the MOT

 

[CMF_frank2]

pic 2

 

[CMF_frank2]

passed the emissions with flying colours today (with fusion nistune board, and SR20 topfeed injectors, and a pretty manky primary cat)
.005 CO (max .3) and 24ppm HC (max 200)

 

[CMF_Tinky]

Good work Frank amazing it passed !

 

[CMF_frank2]

Tinky WROTE:

"Good work Frank amazing it passed !

thanks tinky and not as amazed as me !
we found why the n/s caliper was sticking, that ring of rust arrowed was totally trapping the piston ! so scraped the rust off, and then gave them a good linishing, and lacquered them

 

[CMF_frank2]

pic 2

 

[CMF_Pierce]

wow frank,

They look amazing. are you going to paint them?..

Could you let me know how you cut them back so well? I've got a rebuilt set of ad22v (i believe) brakes at home and they're all black and grimy, covered in ****, but I want to clean them up like that, for a good painting foundation

 

[CMF_hotfunk67]

frank2 WROTE:

so scraped the rust off, and then gave them a good LINISHING, and lacquered them

http://en.wikipedia.org/wiki/Linishing

 

[CMF_frank2]

Pierce WROTE:

"wow frank,

They look amazing. are you going to paint them?..

Could you let me know how you cut them back so well? I've got a rebuilt set of ad22v (i believe) brakes at home and they're all black and grimy, covered in ****, but I want to clean them up like that, for a good painting foundation

the grinder takes the rust off pierce, then this velcro attachment gets it flat and shiny
and i,m gonna leave them lacquered only

 

[CMF_frank2]

fitted a revised rear crossmember mount, those nylon and rubber insert ones transmit too much vibration when you uprate the engine and g/box mounts (and hp )

 

[CMF_frank2]

and an I/C too

 

[CMF_frank2]

fitted the low comp corsa piston engine and ragged it round mallory park
(onboard from msc member arnold,s glanza)
cooked the engine by 9 laps tho (and needed 6 cups of water in the rad ! )
here,s the damaged shells from cyl # 1

 

[CMF_micratech]

Love this project Frank!! Awesome threads man..

 

[CMF_frank2]

micratech WROTE:

"Love this project Frank!! Awesome threads man..

thanks mate
currently running the TD05 again, and we,ve fitted the fire rings from a CR 1.0/1.2/1.4 mls head gasket under the CG H/G for a tighter seal

 

[CMF_frank2]

pic 2

 

[CMF_Tinky]

Your bell housing looks like Swiss cheese Frank Are you going to locate them by using the tabs in the water jacket? And how will you make a seal? Very cunning idea !

 

[CMF_frank2]

heh
yes those 12 tabs held it in place tinky, and the old CG gasket was placed ontop (silicon sealer both sides)
it got me to work and back yesterday (35 miles) time will tell i guess
we,ve also been doing another side exit this week, 63mm s/s perf and an alloy barrel

 

[CMF_Tinky]

Looks like turbo roller mower conversion is next How long is that muffler! Looks like you've used a piece of zinc storm water downpipe. Are you going to stuff it with fiber glass or S/S wool. Allways thinking Frank ....

 

[CMF_frank2]

i cant touch the push mower tinky (her indoors,s heirloom )
and its some weird elephant skin alloy sheet i picked up, the folded seam came out ok eh !
nearly 4 ft x 5 in dia fills the tunnel somewhat, and 2 bags of rockwool

 

[CMF_frank2]

side exit fitted
and my previous fire-ring issues are probably not helped by the open deck design of the (non auto) blocks.
the cylinders are free to expand and contract independently from the rest of the block eh (cast iron liners/alloy block).
so after 6 months of heat cycle,s, the ebay H/G fire rings lack the clamping force to withstand any boost i guess

 

[CMF_Tinky]

Eeekk !

 

[CMF_frank2]

gonna try out a TD04 soon
and compared the difference while trial fitting (TD05 on the left)
aiming for an 04/05 hybrid

 

[CMF_frank2]

pic 2

 

[CMF_frank2]

lightened and polished

 

[CMF_frank2]

acquired some 20mm titanium bar this week

 

[CMF_frank2]

pic 2

 

[CMF_Seb]

Love that! Much stiffer around the big roundabout you turbo drove me in? ahah

 

[CMF_frank2]

aye seb
the TD04 definitely spools quicker, more diesel-esque than vtec now

 

[CMF_frank2]

pic 2

 

[CMF_frank2]

wrapped the downpipe

 

[CMF_frank2]

and advanced the cams 10 deg for that extra grunt

 

[CMF_frank2]

we,ve been testing an unequal length mani this week, for a bit of subaru burble

 

[CMF_Tinky]

Sounds very Subaru

 

[CMF_frank2]

Tinky WROTE:

"Sounds very Subaru

or maybe a cross between a 2CV and a V8

a TD04 from a GTO this time, non open-air wastegate

 

[CMF_frank2]

and here,s the end result

 

[CMF_Danvillan]

wow that really does sound like a scobby. Sounds good