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

[grahams81]

I then started to work out the pipe routes for that side of the collector, and tacked a couple of pipes in place -

So i have decided which pipes will lead to which cylinders and marked them on the pipework -

I'm sure it will all come a bit clearer as it progresses...
Just got to get next week out of the way then i've got a week off should get plenty done that week.

So long for now

 

[munch8987]

Haha, love the super duper holding brackets (cable ties are fantastic)

That is a fapping huge turbo......much jealous!

At the risk of sounding silly, is that flange plate not going to cause bad airflow to the turbo? Surely all the pipes should join in one hole, not two
I'm not a manifold expert, and in no way have the skills of your self, but just something that bothers me

 

[Scott-o]

It's a twin scroll turbo mate!

Great progress, can't wait to see the mani finished.

The shot of it next to the ko3s is crackers!

 

[joehirth]

That's a twin scroll flange for a twin scroll turbo hotside housing. It's to aid faster spool.

 

[grahams81]

Haha, love the super duper holding brackets (cable ties are fantastic)

That is a fapping huge turbo......much jealous!

At the risk of sounding silly, is that flange plate not going to cause bad airflow to the turbo? Surely all the pipes should join in one hole, not two
I'm not a manifold expert, and in no way have the skills of your self, but just something that bothers me

Cheers mate, well you took a risk and it didn't pay off - Your Silly !!!!!!!!!
The flange is called a T4 divided inlet, this is used on twin scroll turbos....it seperates the flange into two banks of two cylinders. Cylinder 1&4 together and 2&3.
This is so the energy pulses from the engines firing order are seperated, by doing this they don't interfere with each other and the energy is transferred to the turbine wheel more efficiently.
Cheers

Edit - Damn you guys type fast !!!!!!

 

[sirjimalot]

I still think that instead of building a smaller rev happy motor I the turbo struggles then we should employ a smaller Borg Warner to spool up tuther. I'm sure there will be plenty of room for it :/

 

[James.Judd.1]

And here's one I made earlier

Little bit of inspiration for you mate, keep up the good work!

 

[munch8987]

Haha, thanks guys, I've had turbo cars before and present, but never really played about, or read up on all the ins and outs of the actual turbos
Are you going to be running the standard actuator or external?

 

[grahams81]

I still think that instead of building a smaller rev happy motor I the turbo struggles then we should employ a smaller Borg Warner to spool up tuther. I'm sure there will be plenty of room for it :/

You still got those photo's of the little'un in the bay ??

And here's one I made earlier

Little bit of inspiration for you mate, keep up the good work!

Cheers James, i've seen this one before, i think a guy called blueberry or something like that had it, American guy.

Haha, thanks guys, I've had turbo cars before and present, but never really played about, or read up on all the ins and outs of the actual turbos
Are you going to be running the standard actuator or external?

Running with the internal wastegate, i got this type of turbo because of it. It's complicated to run twin scroll with external gates, and there's not too much room to play around.

 

[sirjimalot]

Yeah on my camera.

 

[grahams81]

douch.

 

[Ape]

That turbo is massive!! I just had a twitch!!

 

[CupraElliott]

Are you using a jig for your collector?

Nice work, are you tig welding it?

 

[grahams81]

Are you using a jig for your collector?

Nice work, are you tig welding it?

Cheers, No jig for the collector, just measured it and used the chop saw. Its not perfect the angle is very slightly different on one of the 45 degree bends.
If i was gonna start making them i would make a jig but for one i couldn't see the need.
I am gonna TIG weld it all and back purge it (filling the pipe with argon so no oxidisation occurs) give you a smooth finish on the inside

 

[INA]

But he offered me a EFR8374 Twin Scroll Internal Wastegate that he managed to get his hands on - so i've took it
All paid for so should be with me soon...yey

Sweet!
Looks like someone probably canceled there 8374 Order as thats whats been happening recently. We ordered quite a few of the 7064 and 7670 Twin scroll units last year and had a few shipped to us last week (now in stock). Today , however, I get notification that 3 more 7670's became available so we took them.
This entire EFR deal has been a mess but it sure as hell was worth it! and you can fit the 8374 behind there! one of our GTi's is running one!

http://www.facebook.com/media/set/?...5521354992.372684.294598024991&type=3&theater

 

[CupraElliott]

Cheers, No jig for the collector, just measured it and used the chop saw. Its not perfect the angle is very slightly different on one of the 45 degree bends.
If i was gonna start making them i would make a jig but for one i couldn't see the need.
I am gonna TIG weld it all and back purge it (filling the pipe with argon so no oxidisation occurs) give you a smooth finish on the inside

Awesome, I was going to look for someone local to weld mine, would you be up for it?

I have only got a mig welder you see, I was going to tack it all together and get the rest tig'ed

 

[CupraElliott]

Also what schedule pipe are you using? Undecided between 10 or 40.

 

[grahams81]

Sweet!
Looks like someone probably canceled there 8374 Order as thats whats been happening recently. We ordered quite a few of the 7064 and 7670 Twin scroll units last year and had a few shipped to us last week (now in stock). Today , however, I get notification that 3 more 7670's became available so we took them.
This entire EFR deal has been a mess but it sure as hell was worth it! and you can fit the 8374 behind there! one of our GTi's is running one!

http://www.facebook.com/media/set/?...5521354992.372684.294598024991&type=3&theater

Yeah it was probably a cancelled order - lucky for me, had a look at your GTI, its a mk5 tho isn't it ? Seems a shame to hide the turbo though !!! I can't see that working on mine, theres the propshaft and steering rack (rhd) in the way on mine, awesome car you built there though.
And your right hopefully the efr's will be worth the wait

Also what schedule pipe are you using? Undecided between 10 or 40.

I went with the schedule 10, i think the schedule 40 is overkill. The sch 10 is nice and thick, welded right i cant see it breaking.
And as for me welding yours up mate, im really sorry i've got far too much work to do on my own car at the moment.
Once i've fabbed up my exhaust i could lend you me TIG set-up (as long as you left a deposit to cover it if you broke / stole it)
I probably won't be finished with it till after christmas tho.

 

[grahams81]

Getting there with the manifold...

So i got home early this week, i went with the missus to the hospital for a scan today, everything was good, really happy.

I managed to sneak into the garage around dinner time and got cracking on the manifold build.
I wanted to get the collector finished so cracked on with that.

Because of the position of the turbo i couldn't use a perfect v for the second collector, i had to use a slightly offset one.
I moved the angle on the chop saw until i got what i thought was right and after loads of moving it around and clamping i started to cut it, i cut the pipe right through at an angle so i could use both parts and turn them round so the angles met together, took ages but just took my time and battled on.

I dressed the ends up i tacked them together, then mounted it in the chopsaw to cut the end off.

After i chopped the end off -

I then cut the ends to length and started hammering the end into a square shape, then tacked it onto the flange....... took ages to get it right but im happy with the end result.

You can see the angle of one tube is almost straight - that was to give more clearance to the rocker cover -

Inside shots -

Once i have finished final welding the collector up i will us a die grinder and smooth out the inside of the collector just to take the edges off.

Feeling quite happy with myself i decided to use so trusty cable ties on the flange and just try it in position -

I then decided i needed to make a brace to set the position of the collector in relation to the head flange so i could start playing around with the headers on my spare cylinder head.
I found a couple of lengths of m6 stainless studding so used them....
First bit on -

Break for pictures..........

 

[grahams81]

Added another bit -

Tried it on to recheck everything still fitted -

It was still flexing / abit wobbly so added another tie piece -

Mounted the flange on the engine and then loosely bolted on the turbo -

The turbo is far too heavy to be supported offof a couple of bits of studding so it's just propped up with a box for now.

I've gotta go upto my works HQ's tomorrow so won't get an work on the car done tomorrow, should get the manifold all tacked up this weekend tho so thats nice.

Anyhow so long,

Graham.