Turbocharger Posted September 23, 2008 Author Share Posted September 23, 2008 Thanks Lara, sound advice. The potential consequence of losing all the engine oil shook me up a bit and the old turbo's back on at the moment while I have a second go at getting the proper bits in light of what I've learned. I hadn't considered the manifold to be a problem but I know a machine shop so I'll drop it into them for skimming - obvious when you say it really... I've already had it apart to match the manifold studs and the local hose chap is making up the right oil drain and water pipes so I don't risk the rest of the engine again. The boost control is my sticking point although I think it'll work out ok. I can't run it with the vanes fully closed (small turbo) because the diaphragm I have is the 300Tdi wastegate actuator. It doesn't start moving until 0.8bar so it'll control steady state but the turbo hits surge before it can react. The answer is in the spring tension but I don't think it's an adjustable unit. I don't want to spend my ££ on a diaphragm until I know the rest of the principle will work, although in reality I'm getting towards that point now. I'll gather the right parts to make it reliable, pipe it up again in a few weeks and then start the enjoyable part (for me) - fiddling with a control system. It's encouraging that you reckon it'll work with pneumatic control, and thanks for your input - your comments are well received. Any recommendations for a suitable boost diaphragm? Quote Link to comment Share on other sites More sharing options...
JimAttrill Posted September 23, 2008 Share Posted September 23, 2008 Yes, keep it up as it is a most interesting project. We are all watching you Quote Link to comment Share on other sites More sharing options...
Lara Posted September 23, 2008 Share Posted September 23, 2008 Thanks Lara, sound advice. The potential consequence of losing all the engine oil shook me up a bit and the old turbo's back on at the moment while I have a second go at getting the proper bits in light of what I've learned.I hadn't considered the manifold to be a problem but I know a machine shop so I'll drop it into them for skimming - obvious when you say it really... I've already had it apart to match the manifold studs and the local hose chap is making up the right oil drain and water pipes so I don't risk the rest of the engine again. The boost control is my sticking point although I think it'll work out ok. I can't run it with the vanes fully closed (small turbo) because the diaphragm I have is the 300Tdi wastegate actuator. It doesn't start moving until 0.8bar so it'll control steady state but the turbo hits surge before it can react. The answer is in the spring tension but I don't think it's an adjustable unit. I don't want to spend my ££ on a diaphragm until I know the rest of the principle will work, although in reality I'm getting towards that point now. I'll gather the right parts to make it reliable, pipe it up again in a few weeks and then start the enjoyable part (for me) - fiddling with a control system. It's encouraging that you reckon it'll work with pneumatic control, and thanks for your input - your comments are well received. Any recommendations for a suitable boost diaphragm? Tell you what! I will make you an adjustable canister, then you can play all you like. (free) I will give it a tensioner screw but you may have to change the springs etc, I will make it disassemble-able for easy playing. Send me your address and I'll post it. Will need a week Lara. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted September 23, 2008 Author Share Posted September 23, 2008 Lara - you rock, thank you Quote Link to comment Share on other sites More sharing options...
Lara Posted September 24, 2008 Share Posted September 24, 2008 Pleasure Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted November 7, 2008 Author Share Posted November 7, 2008 Quick update - Lara's bespoke diaphragm has landed at my office - and promptly disappeared into our internal mail system Looking at my calendar I'm not going to have time to get it up together before the Peak District trip, so I'd better put the old turbo back on it - again. Next time I'll do the job once, properly, and try to integrate my jumbo intercooler into the same job too. Anyways, I took some of the advice above and had the manifold skimmed flat for twenty sheets: and bought a new manifold gasket, although I'm not sure there was anything wrong with the old one. Now I've got two types though, any thoughts on which I should prefer? Quote Link to comment Share on other sites More sharing options...
Timmy511 Posted November 7, 2008 Share Posted November 7, 2008 looking at that manifold, why dont you while its off, get ze dremil out and atleast try and flow it a bit! just neaten up all the internal welds that you can get to and make all the end of the bores round, itll create less turbulent gas flow into the turbo which will help and if you want to be porn build a difuser into the exhaist down pipe to give a smooth gas flow into you exhause and allows the exhaust to exit faster. on reading this thread, my question is, did you measure the original exhaust mainifold? did you use the same dia tube to make the new one and how close are the branch length to the original one? Quote Link to comment Share on other sites More sharing options...
JimAttrill Posted November 8, 2008 Share Posted November 8, 2008 The top (silver colour) gasket is for a 200Tdi, the bottom one is for a 300Tdi. You should be better off using the 300Tdi one. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted November 8, 2008 Author Share Posted November 8, 2008 Thanks Jim - back to the parts shop. Timmy - I thought about tidying the welds up but they're not as bad as the photos show and there's a lot more about nailing on a homebrew turbo from a different engine that will reduce efficiency before I start to worry about diffusing gas flows between different places! It's a diesel so the massflows are lower, and if I'm looking for benefits at the low-end speed range of the engine then it's even less important. Quote Link to comment Share on other sites More sharing options...
will_warne Posted November 8, 2008 Share Posted November 8, 2008 Turbo, I have to say the manifold doesn't look great. I'm sorry but the internal welds are really bad - as a minimum I'd have another internal weld laid on top of the existing ones, reskim the mounting surface and then work the welds with a die grinder/dremel to port match. To ensure the turbo spools up as quickly as possible you want to keep the gas velocity is as high as possible so port matching is vital. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted November 8, 2008 Author Share Posted November 8, 2008 It really isn't as bad as it looks in the photos, the flow will be pretty smooth. Not perfect, but good enough. I did used to work for Cosworth, remember... Quote Link to comment Share on other sites More sharing options...
will_warne Posted November 9, 2008 Share Posted November 9, 2008 It really isn't as bad as it looks in the photos, the flow will be pretty smooth. Not perfect, but good enough. I did used to work for Cosworth, remember... Not just making the tea, I hope Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted November 9, 2008 Author Share Posted November 9, 2008 Ooh, handbags at dawn from the vapour king... I'll put the OEM turbo back on (again ... sigh) and look at it all again in December. Quote Link to comment Share on other sites More sharing options...
stuntman Posted November 10, 2008 Share Posted November 10, 2008 Keep it up John, I'm really interested in this build. Your forging a path for the rest of us bench top builders. I've just finished building a 110 from the ground up and I really want to stick a variable turbo onto it Quote Link to comment Share on other sites More sharing options...
will_warne Posted November 10, 2008 Share Posted November 10, 2008 Ooh, handbags at dawn from the vapour king... :lol: Everyone always comes back to the vapour... Simply, I could tell people what I'd done and what I'm doing but they'd either tell me I was wrong or that I had spent too much money. When it's done all will be revealed - unfortunatly for me that won't be before the 29th of this month Quote Link to comment Share on other sites More sharing options...
white90 Posted November 11, 2008 Share Posted November 11, 2008 Will never mind as only Les stumped up at his missed dealine Quote Link to comment Share on other sites More sharing options...
will_warne Posted November 11, 2008 Share Posted November 11, 2008 Will never mind as only Les stumped up at his missed dealine Has anyone made a deadline yet???? Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted November 11, 2008 Share Posted November 11, 2008 Has anyone made a deadline yet???? I've got a vapour deadline scetched out, but not got around to making it yet Quote Link to comment Share on other sites More sharing options...
will_warne Posted November 12, 2008 Share Posted November 12, 2008 I've got a vapour deadline scetched out, but not got around to making it yet :lol: Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted November 18, 2008 Author Share Posted November 18, 2008 WOW! Julian has created something that looks like Wallace and Gromit should be employing it in some mission-critical role. In my rather extended(!) VGT install this very exciting component will be pivotal ... after the forum laning trip, anyway. I can now see why it took two weeks to get from Goods Inward in work to my desk - somewhere along the line the label addressing it to me got stripped off, so it was an anonymous 'non-bus part' floating around the stores for a while. I need, again, to thank Julian for his charity in progressing my VGT challenge. Now let's see if the whole idea works... Quote Link to comment Share on other sites More sharing options...
T1G UP Posted November 18, 2008 Share Posted November 18, 2008 If you need anymore welding done then bring it round here. it hurts my eyes looking at that! Quote Link to comment Share on other sites More sharing options...
Lara Posted November 20, 2008 Share Posted November 20, 2008 With great pleasure. And remember that once you have set the spring rate etc, you can cut all the mounting screws etc to length and tidy things up. you will see why I left them all long for you when or if you need to dis-assemble / assemble it to change the spring. Lara Quote Link to comment Share on other sites More sharing options...
gruntus Posted November 22, 2008 Share Posted November 22, 2008 Hurry up already!!! I've been following this thread for ages and I can't wait to see the results Lara, if thats something you "knocked up" for free I am over-awed!! Cheers G Quote Link to comment Share on other sites More sharing options...
Lara Posted November 22, 2008 Share Posted November 22, 2008 Lara Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted November 23, 2008 Author Share Posted November 23, 2008 You and me both, but I ran out of time before the forum laning trip, so it's back on the OEM turbo for now... Quote Link to comment Share on other sites More sharing options...
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