567 replies to this topic

[El_Freddo]

Those heads! So shiny!

What’s with the turbo oil return port being blanked off? I’m guessing you’re running a different turbo oil return line or is this the left over of the twin to single turbo conversion? I’m not up with what was originally in this vehicle.

House Reno’s and emptying boxes - imaging adding kids to that mix. Actually that won’t work! It’s something you have to experience to understand!

Cheers

Bennie

[Barbbachello]

Its the oil drain for the primary turbo, which is on the passenger side head. No turbo there anymore so no need for a drain there. Theyre notoriously tricky to plug normally as theyre a press fit factory so i left the pipe in there and it just had a rubber cap.

Had the head man machine up a billet plug thats an interference fit

[allpaw4]

Nice work on the house man. Welcome to the shitshow that is old house ownership, as it appears you have experienced straight out of the box now lol
Hopefully nothing too much else rears its ugly head!
Some nice purchases on the car side of things too!
Keen to see how it all progresses

[El_Freddo]

That makes sense Barbs. Looks good! And sounds like a neat solution to that issue.

I have a head that I noticed is missing this exact port since having them machined - when I took it off the block it was folded over on itself and somehow hammered flat. I might have a goat making the same thing now I have access to and experience on a lathe.

Cheers

Bennie

[Beckers]

Had the head man machine up a billet plug thats an interference fit

My engine guy, tapped a thread and screwed in a allen key plug, with some tread sealer.

That plug does look nice though

[Barbbachello]

Nothing to do at home while the floors are being sanded so was able to get into the shed last night and bolt the heads on

Shiny bits



Fancy rubber coated RCM 1.1mm head gaskets


Heads on. 100ftlbs of torque on the studs is fairly nerve racking when the stud turns that tiny bit more into the block instead of torquing the nut


Long runner finally arived so popped it on for a photo shoot


Short block needs a good cleaning but couldnt do that without the heads on yeah

[Barbbachello]

Stuck on a new sump with the existing KillerB pickup and baffle plate


Lashed out for some new heater core lines from a 5/6 GC8 instead of the cut up 25D/turbo stuff. New dipstick tube as well


New oil filler neck


And thermo housing cos why not


With some easy wins out of the way put the bare long block back in the bay so i could get started on the fab work.

New up pipe with vband connection to the headers and turbine housing


Looking good



With that sorted I got stuck into moving the external wastegate onto the headers as Ill be doing a 3.5" dump pipe and it was already tight with it out the back with the 3" dump. Found the first hurdle here of there not really being enough room under the car to do a nice 2:1 Y merge without removing the guard liner which i am unwilling to do. So instead Ive done a 45 degree off the top runner turning it into a T where it goes to the gate or up pipe. Then ill merge the other runner into this section and stick the gate on the end. Plenty of room in the front of the engine even with the radiator and fans in


The 90 degree merge probably not ideal. But it works just fine for V8 log turbo manifolds so im calling it good

[Barbbachello]

After finally tracking down and paying $25 shipped for an 80c oil pump oring I was able to get the new timing case, cam gears, oil pump and timing kit on

 

Was quite cooperative and only took 2 or 3 goes to get lined up

New crank pulley and bolt as they are also getting on in years and starting to fly apart


Fresh


Also acquired some metal halfmoon seals to handle the up pipe heat better


Engine assembled and glamour shot of the turbo setup


Also dropped the intake manifold off to get powder coated in some fresh wrinkle red

[El_Freddo]

Awesome effort Barbs!

Why couldn’t you get an oil pump O ring from the dealership? Surely they wouldn’t have asked $25.80 for one! Although, inflation so who knows.

Interesting that the cam gears are plastic except 1.

Keep up the good work.

Cheers

Bennie

[allpaw4]

The metal cam gear is for the proximity sensor for cam position Bennie, they need to be metal pickups for them to work, and its easier for the entire gear to be made from metal as opposed to a sensor plate behind the gear like the crank sensor plate on the H6 flywheel.

Looks like its going to be a great thing Nick!

Cant wait to see it all bolted up once its done!

[Barbbachello]

Funnily enough the late 90s trigger gear was plastic with metal posts in the back

Dealership wanted $10 for the oring, but didnt have it in stock. Nearest one was like 2 hours from home. Could have gotten them to order in but the week i was trying to get it I didnt have the car so couldnt get to the dealership during lunch

[Barbbachello]

Been spinning wheels on the fabrication for the last few weeks. The merge of the runners for the wastegate idea fell apart at implementation as i dont quite have the skills required. Ended up having some very tight spots to weld that i physically couldnt do. Was left with a manifold worth scrap value so cut out everything and set about repairing it. Figured it was currently worthless so worst case its the same best case its fixed.


Thankfully, fixed


With that idea abandoned I was left with 3 options; buying another gate, running 1 gate off 1 bank, putting it out the back where it was previously

I ended up with 2 gates cos its cool lol


I downloaded a template for perfect notching of pipes and it was absolutely worth doing


IYKYK


With that finally sorted i was just left waiting for the long runner to come back from powder coat. I couldnt start the dump until the up pipe location was fixed, which i couldnt do without the intake manifold as i couldnt lock down where the turbo would fit as its very tight. Picked the manifold up this morning and its looking minty

[Barbbachello]

Continuing with the trend of cutting up metal to turn into different shapes

I discovered the turbo was on an angle of around 35~ degrees. Garrett spec is +- 15 to allow the oil to drain properly. So up pipe came back out and got chopped up to remove some angle, which tilted it into the manifold... A few more hours of cutting and grinding came to a 15 degree angle and the turbo brought forward to allow space for the 3.5" dump

 

Speaking of dump pipes it looks like this



And modified mid pipe to meet up with it and replace the flange with a vband


Stoked with how its come out. 3.5" out of the turbo and down the firewall then back down to 3" under the car

[El_Freddo]

Neat work as always Barbs!

You seem to have the pipe work down-pat - something I’m yet to learn properly!

Cheers

Bennie

[allpaw4]

Gonna look mint! Some nice work there.

[Barbbachello]

Exhaust fully welded up


Gates and screamer pipes installed


A repeat of my BG and i ordered a late model dip stick tube which has air pump clearance built in, so it moves over into where the AC lines want to live. Dont know why i never actually looked at a twinscroll parts diagram but the tube is the same part as a single scroll... Finally got that sorted after paying way too much for a new single scroll tube


Mounted the fuel reg to the bell housing as the previous mounting boss no longer exists on the long runner manifold


Ran the vacuum lines for the waste gates through the inner guard. There are 2 tee pieces under the car which splits the single hose to the top and bottom ports 


Intake manifold finally bolted onto the engine

[El_Freddo]

Watching your build I wonder how you’re so patient with your build!

Only got screamer pipes I’m guessing, no plumb back wastegate action. That could be interesting on the road at night…

Cheers

Bennie

[Barbbachello]

Watching your build I wonder how you’re so patient with your build!

Only got screamer pipes I’m guessing, no plumb back wastegate action. That could be interesting on the road at night…

Cheers

Bennie

Can say the same about your RS lol. I often have to tell myself that i dont HAVE to have everything this weekend and its done when its done

No plumb back. Just screamers

[El_Freddo]

Can say the same about your RS lol.

Touché. I have a number of projects to keep me busy, I’ve only seen one of yours at a time.

[Barbbachello]

Big weekend doing the last 10% that takes all of the time as usual

Started putting more and more things back on the engine 


Fuel lines sorted out with the ethanol sensor moved to the low pressure side after the reg and tucked up on the tower


Ended up swapping back to the OEM power steering hardlines. These fit much nicer with hard bent steel lines as the AN lines were hard up against the oil drain fitting. Not really sure how it ever worked or why i swapped them out in the first place tbh. Excuse the spaghetti it all needs tidying up


Put some fire sleeve over the heater core hose near the dump pipe and tucked the wiring loom back a bit further


Swapped the manual facia onto the STI cluster and put everything back together


and its alive. This is actually the 3rd or 4th start as the first couple had a fuel leak and would rev to 3k rpm. Long story short the throttle cable was too tight lol and holding the throttle body open 5%