Track Elan

[Dave M]

how about jet-hotting the turbo itself? or at least the exhaust side -- what does that do for efficiency, etc ??

Might help with corrosion? You can see just sitting in my garage the thing already has surface corrosion. Add 1600 degrees and things turn a nasty shade.

[Doug]

better keep assembling though if you are to get out here in 6 weeks

[Dave M]

better keep assembling though if you are to get out here in 6 weeks

Yes...all the new bits won't be shiny and pretty if I come out. Those will be the "winter project". And that should be the ONLY winter project this year.

[Dave M]

Oh, boy. It's starting to get so close now I can almost taste it! Or maybe that's a few metal shavings in my mouth from the last bit of grinding I did tonight...

The pipes have been final fit and are going back to the welder Tuesday to be completed. The external wastegate was a bit tricky to line up (and may be more tricky to weld), but I've got an interesting solution/setup. The interior is complete and the seats are amazing with the harnesses. I will not be moving once anchored in! Here's a pic of behind the passenger's seat with the speaker enclosure removed and replaced with new carpet.

http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph

Most everything is now wired in the engine bay including a relocation of the O2 sensor (help clean up the looks under the hood). I was able to put the axles back in, suspension reassembled, coils in, and a bunch of miscellaneous other this past weekend. I even put a new oil filter on! Fluids should be in tomorrow.

The only main items left are the radiator and intercooler. Because the IC is much wider than the stock unit, I had to modify the crossmember support in the front. US owners can relate to this piece.

Before:

http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph

After (not welded/painted yet):

http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph

One of the IC brackets will hang from this piece, too.

So a little ways yet to go, but not much to do until the welding is done. It is a great feeling to be getting this close!

[F1 LOTUS]

Most everything is now wired in the engine bay including a relocation of the O2 sensor (help clean up the looks under the hood).!

Details
A couple of things I wondered about related to this...

Locating the O2 sensor downstream of the Turbo, is this the optimum place? I'll have to check in the Bosch Handbook.

Cleaning up the looks under the hood...as I was laying-out the Spark Plug Cover, it struck me how rude the Oil / Air Separator looks? It's the highest part of the motor (probably must be so?) and it's ugly, and it's held by a big heavy bracket. Wouldn't it be neat to either: - Mount it off the Spark Cover, design it into the cover, or, find a smaller-neater unit and mount it out of sight [/quote]

[Dave M]

Locating the O2 sensor downstream of the Turbo, is this the optimum place? I'll have to check in the Bosch Handbook.

Good point, but it will only be about 4" further down the exhaust than the stock location. I'm just putting it on the "down" section of the pipe leading out of the turbo.

Cleaning up the looks under the hood...as I was laying-out the Spark Plug Cover, it struck me how rude the Oil / Air Separator looks? It's the highest part of the motor (probably must be so?) and it's ugly, and it's held by a big heavy bracket. Wouldn't it be neat to either: - Mount it off the Spark Cover, design it into the cover, or, find a smaller-neater unit and mount it out of sight

OK - this is a winter project I can handle! No engine and/or transmission removal! Is this something that needs to be set high in the engine bay for the air to come "up" to - similar to the coolant tank?

PS to my prior message: I also installed some heat shielding material for the oil pan since the exhaust is nearly touching right at this point. Going to be using it in a few other places, too.

[F1 LOTUS]

I just wondered if there would be any benefit from locating the O2 sensor upstream of the turbo, maybe in the spacer

[Dave M]

I just wondered if there would be any benefit from locating the O2 sensor upstream of the turbo, maybe in the spacer

That would be the best location - right where all cylinder gases come together. It probably could be designed into a spacer. Like everything in that area however, the trick is getting to it for installation/removal. Underneath the manifold/turbo looks like a good, open space, though! Check out the pic of the new downpipe from the turbo I took from underneath the car on the previous page (last picture).

[F1 LOTUS]

Looks like there is already a boss facing sideways on the manifold ready to be drilled and tapped?

[Ashaman]

Are narrow band & Wide band O2s pretty much the same in construction?

I know that widebands are supposed to be ~24" downstream to avoid damage. They will fail if exposed to temps over ~1500F, so they need a little space to allow the gasses to cool....

Dunno if it applies to stock/narrow units or not...?

[Dave M]

I'm not sure it would matter where in the exhaust system the sensor was located as long as the system was free from leaks. The gas composition wouldn't change as it cooled, would it? Granted in our car it is very close to the head, though usually in an NA car, the sensor is forced further down the exhaust because of the header design. Seems my Subaru's is a good 24+" downstream. The heat affecting the sensor is a good point - though I don't remember the instructions from the sensor I used to have stating a minimum distance. Maybe certain sensors are located closer because they are not internally heated?

[Dave M]

After a week of delay thanks to a nasty cold, I’ve finally had the energy to get back at the car. I received the modified front bracket back from the welder, painted it and have it installed. That also allowed me to mount the new intercooler and finish the radiator install as well. Also during a late evening of work on Tuesday, I was able to get the front crossmember back in and put new gaskets in the exhaust system. Last night was spent installing most of the coolant hoses (can’t wait for the Samco kit! ), new heater valve, brakes (including swapping the old, cracked rotors), and any other little bits that can be put in now and not interfere with the turbo removal. Once I get the piping back, I’ll test fit everything, then determine what parts need to be assembled first before going back in the car. The manifold, turbo adapter, turbo, downpipe, and external wastegate may all need to go in together. That would be a real trick…

Here’s links to the before and after pics of the front bracket modifications:
http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph
http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph
http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph

Here’s also some misc pictures of the “new and improved” boot – with lots more space in the corners thanks to a few items removed.
http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph
http://pg.photos.yahoo.com/ph/themeyers ... pg&.src=ph

Finally, here are some pics of the IC in. You can see the bracket above in pic #2

[Dave M]

I wish this entry was to tell you the car is running and was at the engine shop on the dyno right now, but it appears that day is a few weeks off yet. The car is relatively complete with the exception of the intake and exhaust piping *still* in process. I have put all fluids in the car, mounted the new FMIC, primed the oil pump, even mounted the rear wheels…everything I can do without the new O2 housing / external wastegate assembly. I can’t put the turbo in until this piece is done as both pieces may need to go in assembled in order to fit. Otherwise I’d have started the car by now. The only issue I’ve come across so far has been a slight leak in the cooling system. One of the hose connections leaks ever so slightly. Thankfully it is in an easy to reach place and I should have it sorted rather quickly.

Frankly I’m pretty bummed about the recent lack of progress and was sick of staring at the car stuck in the garage about 3 months ago. Guess I’m being taught a lesson in patience through this whole thing. There *is* a light at the end of the tunnel and I’ll be driving shortly, but the progress on the final bits has been so slow (and so out of my control), I’m about to go out of my mind.

Hope to have better news for you all before Thanksgiving. For that I’d really be thankful!

[Dave M]

Wouldn't ya know it? Just about the time the car is ready to roll (maybe this weekend) and here's the forecast:

[Monty]

Dave at least it`s coming together and look forward to the dyno results. It`s a shame u didn`t have the Samco hoses to go straight in

Keep up the good work

[Dave M]

The welding is finally done! Due to some delays (the guy was doing it on his own after-work time so I can't blame him), I'm a lot farther behind on the "drive" date than planned. But at this point, given the above forecast and the expected future weather, I guess I'm in no rush now. Sadly, the CA trip will be postponed until spring (see the other thread), but all in all it may be for the best. Less rushing, more getting things done right the first time.

That said, the pipes are great and are ready to go in. At first I thought I'd get them in, drive the car and get it tuned, then this winter get them coated along with some other parts. Instead, with the CA trip not forcing the issue, I've already sent them out to Jet-Hot within a day of getting them! I figured I'd rather put things together once, than run the car for a bit, then take a bunch of parts out and have them coated later. No reusing gaskets, etc. Besides, the coolant leak is still there (arg! Samco hoses ready?! ) so I'll sort that first while the pieces get all nice and pretty. I've sent all pipes, a few brackets, and the turbo's turbine housing to be coated.

Below are pics of the finished downpipe/external wastegate. The following link has pics of the rest of the pipes including the small nubs put on the ends to keep the turbo hoses from blowing off at high boost. Scroll to the bottom of the album to see all recent photos.

http://pg.photos.yahoo.com/ph/themeyers ... ?.dir=1d43

[Doc Fizzix]

DAM!

How much will they charge to make another? I NEED ONE

[Dave M]

DAM!

How much will they charge to make another? I NEED ONE

Actually that was my creation. I just needed someone to weld who wouldn't make it a smoldering pile (like I would have)!

[Doc Fizzix]

Well, when do I get mine?

[Houdini]

Dave,

Looks great! I have the A/C to contend with so mine will not be a nice bend like you have, but then again I'm going to be internally wastegated.(For now). By the way are you using a wide band O2 sensor, or a regular one? As long as I'm asking, what brand are you using?

,Russ