Grahams81-Leon 4wd, Big Turbo - Back in the saddle :-)

[tom t]

im pretty sure ive seen somewhere people use a litte shock absorber type brace. ive seen somewhere before had it mounted to the strut turret holding the turbo and it allowed for movement, wasnt on a leon though. cant remember where i saw it! might be an idea

 

[csd_19]

I then reconnected the gearlinkage mounting points and also found that the 6 speed quattro box has round ball type connectors on the shifting cable ends and the ones in the leon are just round pins with clips on the end.
I will just take the shifter connections off and cut the balls off and drill and tap it the levers and make a quick shifter while im on.

Do you still have the old leon gearbox? If so just whip the shifters off that?

 

[cupra.al]

im pretty sure ive seen somewhere people use a litte shock absorber type brace. ive seen somewhere before had it mounted to the strut turret holding the turbo and it allowed for movement, wasnt on a leon though. cant remember where i saw it! might be an idea

like an engine damper.

 

[euanlowe]

Think I know what Tom is talking about, its like an adjustable tie bar with rose joints at each end one end onto the turbo and the other onto a frame that bolts onto the cylinder head

 

[grahams81]

Cheers for all the comments, In terms of turbo bracing, i'm planning on making a bracket to mount offof the gearbox mount, so as the engine moves the turbo moves with it. It doesn't need to be too strong - i just want to take some weight off the manifold so its not all hanging off the head.
I may use a block of PU to allow for movement for thermal expansion, or just use some 2-3mm stainless so it can bend as it needs too.
Cheers Graham.

 

[grahams81]

Do you still have the old leon gearbox? If so just whip the shifters off that?

Nah i gave it away it's ok i'll manage

 

[cupra-barn]

Gotta give it to you Mr Graham, I wouldn't have a dicky doo clue where to start with half the crap you're attacking, fair play mate loving the thread!

 

[grahams81]

Gotta give it to you Mr Graham, I wouldn't have a dicky doo clue where to start with half the crap you're attacking, fair play mate loving the thread!

Cheers Mate, glad your enjoying the read, i'm enjoying the build !!

Small update -

I got back from work this morning and found my goodies had been delivered.

After looking on the internet to see if i could buy a metal cutting disk for my mitre saw i found that the proper ones were quite cheap so i bought myself this -

Didn't fancy hacksawing / using a angle grinder to cut the Schedule 10 Stainless pipe, plus it will be easier to weld up if the joints are more precise.

Also got another 3 lengths of 1.5" SCH 10 stainless pipe as the new design is gonna need more material.
I was undecided whether or not to step up the size of the runners where they join to 2" so i bought 4 2" bends and a couple of 1.5" to 2" reducer.
After seeing the pipe i don't think i will step the size up, just bring all 4 pipes to the collector on the flange, its gonna be a bit more complex but i've got plenty of room to work with and plenty of materials.

I decided to go and get my Argon bottle refilled up in Newcastle, then i went to pick up the rest of my parts from Lookers in Teeside -

I ordered all the parts for fitting the LCR bumpers & Side skirts & FR bumpers.
New grills & Badge -

Not shown but i got some brand new side skirts

So i've got a really big weekend planned on the car. I will update again when i've done some graft !!

 

[Damoegan]

Looking forward to the mani build mate

 

[Phillc]

Graham, i have the same saw as that and i have found its quite hard to cut straight as the blade pushes out as you cut and the clamps not the best, just though i would share that with you. Good work by the way, i am now waiting for the cam belt tensioner and breather insert from IE that you fitted, i knew i shouldn't look at other peoples build threads as i always see things that end up costing me money.

 

[sirjimalot]

I called round Grahams yesterday and severly disrupted his Manifold build! (not that he was stuck! which he was)

After deliberation and loads of Sports Mix (did you know they had dropped the TURE?) he had figured it out!

I went back round today to do some comparison shots between the K03s and the BW, he made progress too which im sure he will update tonight,

But here are the shots!

 

[Murdered LCR]

****ing hell

 

[Miller 20vt]

****ing hell

2nd that!!

 

[Cupra R]

3rd that

 

[cooky25]

Tru dat!

 

[Gooner_Mike]

Chuff me that's a big tubby....

 

[cupra-barn]

Fook a dook that's MASSIVE!!

 

[JME]

nothing.............boooost.....

 

[joehirth]

Struuuth

 

[grahams81]

Anyhow thanks again for all the comments guys !!!

Graham, i have the same saw as that and i have found its quite hard to cut straight as the blade pushes out as you cut and the clamps not the best, just though i would share that with you. Good work by the way, i am now waiting for the cam belt tensioner and breather insert from IE that you fitted, i knew i shouldn't look at other peoples build threads as i always see things that end up costing me money.

Thanks for the tip on the cutt off saw mate, i know what you mean with the spending, everytime i look on tinternet i see something i think i could do with (not need but would be nice ) I need to start tightening the purse strings a little, should be saving up for the young-en coming but can't turn my back on the project!!!

I called round Grahams yesterday and severly disrupted his Manifold build! (not that he was stuck! which he was)

Cheers for putting up the pics Jim, and yeh i was stuck !!! Hours of staring at 4 pipes imagining how they were gonna fit into 2 square holes !!!!

Thought my wife made a cracking statement when she said why are the holes on the flange / turbo square when everyone uses round pipe for the manifold.... why don't the turbo manufactures just make the inlets round.......i had to say well i suppose that would be too simple !!!

Anyhow thanks again for all the comments guys, can't believe how big the turbo looks next to my old k03s.

So yesterday was a day of head scratching and moving the tubo around in the engine bay, did start messing about with pipes trying to get a feel for how the collector should be but didn't get anyway... Big thanks for Jim coming round and totally stopping the thinking process

Today was a better day, i started by taking a couple of 45 degree bends, marking them up and cutting them roughly with my plasma cutter, i then spent about an hour trying to get the edges nice and square.
The reason i used a plasma cutter was i couldn't get the small fittings in the vice of the chop saw.

I gave up filing after a while and stepped back and had a think, i then tacked a 45 degree bend onto a length of straight pipe so i could hold it in the vice of the saw.
I cut it, and the finish was really good. So again had to think how to do the other pipe (opposite hand), in the end i tacked on 4 - 45 degree bends each one the opposite to the previous the cut the final bend.

I then dressed them up and tacked them together -

I then needed to cut the bottom square for fitting to the flange, to do this i again welded the collector to a piece of straight pipe so it could be cut in the chop saw -

So after doing this i tried it on the flange and there would have not been enough room for the bolts / nuts to hold the turbo on..... so i cut a piece of pipe up about 10mm long and cut it, i then opened it up and bent it to mate the collector to the flange.

I then tacked the collector to the flange -

Break for pics........