port size 22mm

[rob/d]

Got heat shields buffed up and lacquered.
V.H.T painted manifolds and gave them a clear coat of high temp as well .
Got it all back on the car today , but i will give the car an oil change and coolant swap before starting .
A few pics.
I know that you can't see most of the manifold and down pipe when it's all back together but i truly hate bare cast iron .

[ccb056]

Looking good!

[rob/d]

been busy .
had wheels refurbed and new tyres on .
took car out first time today and ...and........ and ...... no over boost
no leaks , just bit of smoke under bonnet from painted manifold.
bliss

[alan e]

Spent today removing the turbo not a easy job does anyone know where i can get it ported also one of the studs snapped flush with turbo housing which will need drilling and re tapping.

[muley]

Spent today removing the turbo not a easy job does anyone know where i can get it ported also one of the studs snapped flush with turbo housing which will need drilling and re tapping.

If you can take the turbo off, you should be able to port it yourself - it's a walk in the park (covered on the Wiki) I used the set of 'stones' from B&Q to do the job.

Any half decent machine shop should be able to drill and tap your turbo (I had mine done at the turbo rebuilders..)


Jim

[alan e]

Thanks Jim I was thinking of giving it a go the stone you used was it for a drimmel and how did you stop bits going into the turbo?

[muley]

Thanks Jim I was thinking of giving it a go the stone you used was it for a drimmel and how did you stop bits going into the turbo?

No, the stone was on a shank and just fitted into a chuck on my regular drill.

I suspect it was one of these - I remember buying a set.

http://www.diy.com/departments/bosch-gr ... 088_BQ.prd

IIRC I just stuffed some rag down the orifice before I ground away..

Jim

[lotusflasherman]

Fitted a big bore stainless exhaust to my No 2 Elan and need to port the wastegate. I have a spare turbo but it's got some cracks in the wastegate port seat so maybe that's the one to play with...

crack sm.JPG

Question is "How big can you go? Can you go too large with regard to any gasflow and back pressure issues ?" Sealing of the original flapvalve will not be the constraining factor as I have a solution to enlarge it.

Previous owner of my Eclat Riviera (2.2 912 engine) had it serviced by a local 'race tuner', well he raced a Formula 4 car anyway, but the service history was a sorry tale - He'd fitted a QH cambelt (actually for a Bedford van - right length & teeth but only 2/3rds the width) and it broke and bent some valves. He replaced valves & cambelt just before I bought the car. When I looked through the parts bought I immediately bought and fitted a Lotus cambelt & started looking through the paperwork and saw 5 exhaust valves & 4 inlets with 907 (2 litre) prefixes. After a few months I lifted the head and removed 907 valves and fitted 912 valves. 907 exhaust are flat top, 912 have slight dish so 5 very low mileage flat top exhaust valves got put in a box. These exhaust valves have a diameter of 30.8mm and looks ideal material and size to manufacture an oversized turbo flapvalve so perhaps I've finally found a use for at least one of them..... see photo

valve.JPG

Anybody got any useful comments or suggestions before I start....

Phil

[dapinky]

Phil,

I like the thinking on the flap valve......

.... mainly because this could be one more chance to gloat to my wife about not throwing anything away which may come in usefull one day.....

.... my Elite 503 went to a new home 20 years ago, but I still have the 4 valves which were salvaged from the top-end re-build when the belt snapped!!!

[lotusflasherman]

Phil,

I like the thinking on the flap valve......

.... mainly because this could be one more chance to gloat to my wife about not throwing anything away which may come in usefull one day.....

.... my Elite 503 went to a new home 20 years ago, but I still have the 4 valves which were salvaged from the top-end re-build when the belt snapped!!!

So you could do a bigger wastegate flapvalve too!

I tell my wife "that's not junk - that's my stock of raw material!" but she stills moans that her car has never been in our double garage in the 22 years we've lived here.. Don't know what the fuss is about as I bought her a ST170 Focus with electrically heated front & rear screens so she only has to scrape ice of the sidewindows in winter..

I do find that having been stepping over things for years, I'll finally have a garage clear-out, possibly to make room to do a job in there and then find myself looking round for that odd bit of something that will be just right for the job, only to realize I've only recently thrown it out!