Most liked posts in thread: Build thread as of 6.23.14 (turbo eventual twincharge build. CNC, tig welded, etc )

Had many other evening duties (work, social calls, family stuff) so I only got a few of the parts bolted back on for mock-up purposes of a few parts I am still working on, but they do look nice mounted back in place!


Little in-progress welding shot of the soon-to-be coolant overflow tank.


And finally a little sneak peak at something that is coming soon... very soon...
Should have already been here and it is currently late soon. :fingerscrossed:



All I have to say (for now) is it replaces some retaining washers and will act as part of a seal surface...

If you dig through the other thread, you will find a picture of it in a drawing somewhere and should be able to put 2+2 together.

 

new award to most PITA thing I have done recently goes to!

This intercooler!

Turns out I should have just machined a few pieces myself. While the surface finish was better, the bolt holes that I have to bolt the water blocks too are up to .010" out of position. Which may not sound like much, but it makes things not line up, so I have been taking a dremmel with a tunsten carbide router mill bit and slowly opening holes and ovaling and fiddling everywhere to try and get this thing to work and not mess up the o-rings (I currently can get it all bolted together, but it pushes the o-rings to the side and does not seal 100%)


not a huge problem, just annoying and laborious.




Oh, and I have about 200 extreemly tiny metal slivers (metal splinters) in my hands.. everywere...
(stainless from the laser cut retaining washer replacements)

and they are friggin tiny...

yes, the arrow is pointing at it.
And for scale, that tweezer is pretty small: think what your wife / GF uses to pull eyebrow hairs out.. in fact, these slivers are probably 1/4 the diameter of a hair! if not less... fml...

 

^ inverter machines help to fix that problem.

AC, 2% lanth tungsten with a blunt point, clean metal (prep is key) , and 100% argon make welding aluminum easier than stainless imho.
Just need to worry about thermal capacity and pre-heat is all.

Super easy to fill in large gaps as well if you have decent pedal modulation.
Some of those tight corners I didnt even worry about putting a little piece of metal in and instead left it as a .5"x.5" triangle and just filled in the hole with filler. haha!

 

well.. car is going back down.

On one hand,

YAY!! more parts to make!
and

YAY! going twincharged!

why?

Well I had the throttle pre-turbo. As designed.
It was stated that the comp turbo can handle a vacuum.
And it can.
*but* the turbulence caused by the throttle and short intake path does not allow for a rectifing zone for the flow to re-gain stability.

This means the flow maintains turbulence as it enters the turbine wheels which is causing an uneven loading on the compressor wheel (we think)

but the point of the matter is that it works. Works quite well.

But!

It makes a heck of a whirring sound and it makes me, my other engineering car buddies, and the engineers at comp all squirm, and not in a good way.

Good news is I knew something like this could happen, and had budgeted for it!

So new list of parts that are coming in.

4.5"x2.9"x8.5" bell w2a core. This will be going where the top mount for the SC was.

Synapse synchronic DV (diverter valve)

This will work as the "blow off" for the SC/turbo system

tubing to run it all together.

making a bolt-on adapter that will use an o-ring seat to seal to the front of the OE throttle body (no silicon boost coupler here!)

OE throttle is being re-located post supercharger on the entrance to the intake manifold!
(if I cant have weird turbo response from spooling in a vacuum, I will at least have some throttle response!)

new (to me) intake manifold is on its way for me to cut into / modify for ^^ and vacuum ports

re-locating a2w pump and resevoir to trunk of vehicle.

no interstage cooling. (bell core above is sized to work for this application just fine. it will be post SC )

Working on a method to best bypass SC when wanted (aka when the turbo kicks in)
- current thought is re-working an OE diverter valve to use a spring returned linear actuator that will open during boost. from the SC inlet.

that is all for now!

here is the whirr (i have done subsequent testing and shown that the bearings are fine, and it does not make this sound when not restricting the intake side of the turbine)

Pre turbo throttle vibration - YouTube

 

Why thank you

While I posess many tallents, and I can even do some sheet metal work, I do lack the capability to accurately do complex bends on heavy sheet metal.

So I drew these up and they should be in my possession next thursday. (will be made from .125 6061 or 3003 sheet)



Should have some progress (major progress) next weekend when I have everything here

Some welding this weekend though, so not all is lost!

(new compressor housing here tom. and some pre-SC piping work to complete.
Then I still need to lay out and start making the new w2A ic resevoir.

 

first piece done!
only messed up one about an hour in, so I had to start over.

all the manual steps and other bits and making jigs etc took ~ 5-6 hours just for this one piece. O.O

worth it? worth it.