David P Posted August 12, 2013 Author Share Posted August 12, 2013 (edited) The welder took off the tape and dropped the pieces then couldn't fit the jigsaw back together. Now marked up it should be finished tomorrow. Edited August 12, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted August 13, 2013 Author Share Posted August 13, 2013 Water/meth update good news. Richard at ERL has found that the high speed valve wasn't functioning at pressures over 100 psi, yet as I have a twin-pump set-up the system is running closer to 250 psi. A new one is on it's way. Quote Link to comment Share on other sites More sharing options...
Steve Posted August 13, 2013 Share Posted August 13, 2013 Water/meth update good news. Richard at ERL has found that the high speed valve wasn't functioning at pressures over 100 psi, yet as I have a twin-pump set-up the system is running closer to 250 psi. A new one is on it's way. That will explain it then Quote Link to comment Share on other sites More sharing options...
David P Posted August 13, 2013 Author Share Posted August 13, 2013 That will explain it then It's had us both scratching our heads a time or three and I'm pleased to have that crafty Gremlin finally evicted. With a manifold that's not impersonating a pepper pot and with a working water/meth system, it should at last be ready for the mapping it deserves. Quote Link to comment Share on other sites More sharing options...
David P Posted August 13, 2013 Author Share Posted August 13, 2013 (edited) The good news is; Humpty Dumpty is back together again and fits better than ever has. The flange slips nicely onto the studs, the flexi is clear of the other branch and with clearance for engine mounting bracket. The not so good news is; The welder didn't achieve a proper leak test. The bad news is; I've found another crack which's another missed weld from it's original construction. I'll get a good seal to the flanges and take it back for this little weld and a proper leak test. The welder won't be happy about it, but I'm not refitting it until proven sound. Edited August 13, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted August 22, 2013 Author Share Posted August 22, 2013 (edited) This little project of mice and men to put Humpty Dumpty back together again, degenerated into a pain of many flavours and I won't trouble you with the details. Turtles circle came to my rescue and sorted the trickiest last details of the welding and Shane brought me an O2 sensor to replace a casualty. Thank you both very much. Two-piece flange and a wiggly bit, all welded and purged, with relocated O2 sensor and boss for AEM EGT probe. Pre fit wrap. The back-breaking second-wrapping about halfway. Double-jacked & blue brick under wheel, an adjustable work height to lessen bending and find a sweet spot for the 20 metre Threadawrapathon. The Mummy reborn and Sanctified with a leaking finger. New bulge fits nicely behind engine mounting. Bracket first, then stat-housing, throttle-body, new distributor and cap. Birds eye view of the Tardis. Bottom bracket adjusted to fit. The job is jobbed. During the rebuild I found and fixed a partially stripped thread, right at the tight-position on a bellows clip and it's now boosting to 16psi. Found out when I gave a Beemer a Ziip-by Crackle Pop Bang. The detonation Gremlin is evicted and for the first time, it's giving on the road what it gave on the dyno. This time I remembered to dress the strut and give the throttle cable a couple of mm clearance, that's the last of the contact Gremlins and the end of conducted working noises transmitted to the cabin, the exhaust is quieter too, a definite refinement for the conversion. Edited August 23, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
trebor69 Posted August 23, 2013 Share Posted August 23, 2013 Quote Link to comment Share on other sites More sharing options...
Noz Posted August 24, 2013 Share Posted August 24, 2013 Sounds awesome. Well pleased for you buddy! Quote Link to comment Share on other sites More sharing options...
mellonman Posted August 24, 2013 Share Posted August 24, 2013 Glad to see its made an improvement, Quote Link to comment Share on other sites More sharing options...
listy Posted August 24, 2013 Share Posted August 24, 2013 Quote Link to comment Share on other sites More sharing options...
David P Posted August 24, 2013 Author Share Posted August 24, 2013 (edited) It's running a lot better now, third time lucky my spine hopes. An aluminium weld repair, a tweak to the idler pulley arrangement and the new w/m valve to fit, then it can have a proper mapping. Edited August 24, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted August 25, 2013 Author Share Posted August 25, 2013 (edited) The difference this repair has made is remarkable. There's now a "lot" more power and without the extra working noises transmitted from previous throttle-cable/inner-wing contact, this new found Oomph seems to come from nowhere and has turned it into an Animal on wet roads. Edited August 25, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted August 25, 2013 Author Share Posted August 25, 2013 (edited) Now that acceleration and gear change doesn't include dancing around random detonation events, I can simply press the clitoris pedal and focus on causality. So I decided the time had come to go and play in that mini tunnel I found, it's single track with a hairpin potholed entry then wet good surface and dry hairpin exit. So I dragged a petro nutter away from his Sunday dinner to hold the camera, he was even brave enough to film the first run, confident that I wouldn't turn him into a red smear along the concrete. No smear, but I did overboost the first run and nearly turned his ears into whelks with the resulting BANG. Just enjoying my favourite birthday present. Edited August 25, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
skippyboyo1 Posted August 25, 2013 Share Posted August 25, 2013 Bloody he'll you bounced it in to there didn't you! Quote Link to comment Share on other sites More sharing options...
David P Posted August 25, 2013 Author Share Posted August 25, 2013 (edited) I don't make a habit of it, but without a sideboard nailed on the front it's amazing what Supra's will do with 45 profile tyres on 18" wheels @ 28psi, I learned that trick driving Eastern European roads and now they're ours too. Here's a clean run without overboosting or rev limiting and with a change up into second in tunnel. The sound continues resounding like a bell. Edited August 26, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
Noz Posted August 26, 2013 Share Posted August 26, 2013 Wish mine boosted that early. Dam it! Quote Link to comment Share on other sites More sharing options...
David P Posted August 27, 2013 Author Share Posted August 27, 2013 (edited) With the torque-convertor programmed at 1,800 rpm stall, without holding the brakes it boosts from a standing start. The torque curve is broad and flat and acceleration is constant thrust, even during gear-changes. It pulls like a train in 3rd, from 40 to 140, changes are more for drama and the sheer fun of it than need. You'll get a go in it one of these days and it'll be even swifter by then than now. Edited August 27, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted August 29, 2013 Author Share Posted August 29, 2013 (edited) I'm happy with the exhaust and now attending to a few tinkerings in preparation for the Old Girl to get a proper mapping at last. There's a small leak in the supercharger to charge-cooler flange where I've polished away too much of the aluminium weld and have a pair of proper new hose-tails for the swirl-pot to replace the present chair-legs. The idler-pulley on the front of the engine has too small a bearing to function efficiently, so using an adaptor will be changing it for the water-pump idler I had made, this pulley is slightly smaller and will allow the sky-hook idler to run further away from the supercharger pulley. I'm not happy with the transmission, second-gear is too slow and the clutches too weak and I've become to suspect that the Yank who modified the valve-body has reassembled the check-valves incorrectly, so will hybridise and swap in another box using a stock N/A valve-body with beefed up actuators. The water/meth system is now working, but in need of a pair of one-way check-valves for the twin-pumps. (Ordered) The aluminium welding and pulley-adaptor fabrication are arranged for monday, which will leave just the trans swap and some final tinkerings to set up the now working water/meth system. Edited August 29, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted September 3, 2013 Author Share Posted September 3, 2013 (edited) I've found a little welding and engineering Workshop, where for a drink I can go to and get little jobs done during their lunch-break. It's a bit rural and the field next to where I'd dismantled the induction was invaded by combine harvesters and I had to work in between their passes when the air had cleared a bit and was too busy to take any pics. The charger exit flange has been re-welded on the inside where it won't get polished off and the swirl-pot has a new pair of proper hose-tails that are nice and easy to work with. This workshop is making something that helps makes satellites and the sudden unexpected mega cereal fallout caused quite a stir, so the pulley-adaptor will get done next time. One-way valves are fitted and the water/meth is up and running. Final jobs remaining are to build and fit a Hybrid transmission then swap in some decent plugs and the Old Girl will be ready for; the just about as good as it's likely to get mapping. Edited September 3, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
David P Posted September 6, 2013 Author Share Posted September 6, 2013 (edited) The idler-pulley adaptor will maybe be ready by the weekend, Denso IK24 plugs are ordered, a transmission pan-filter is winging it's way from U.S, and I should have another transmission to tinker with in a day or two. I thought I had the w/m under control, however, there is too much pressure for the new high-speed valve and it needs a gauge on the regulator for adjustment and monitoring. On 13th Sept, the car will have been officially supercharged for a year and was my target for a Gremlin less mapping, yet with waiting-time for the 'things' to complete these last tinkerings and a 3 week lead to get on the dyno, I need just a little more patience. Edited September 6, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
Noz Posted September 6, 2013 Share Posted September 6, 2013 500hp target? Quote Link to comment Share on other sites More sharing options...
David P Posted September 6, 2013 Author Share Posted September 6, 2013 (edited) 500hp target? Yes. But I try and avoid mentioning numbers, just in case it upsets anyone. Here's a clip of the w/m activating @ over 5-6psi that might interest you and how rich under boost the AFR's now are without the LAMBDA sensor trimming fuel out of the map. Cruise is 14.7 on the button, so I need to be a 'good boy' for just a little longer. At around 2-4k rpm in third, first two are gentle, third is WOT and fourth and fifth medium pedal. From the top; AFR - Boost - W/M - EGT. Edited September 6, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
thetrashcanman Posted September 6, 2013 Share Posted September 6, 2013 Sounds awesome dude, car looked great at the anniversary meet Quote Link to comment Share on other sites More sharing options...
David P Posted September 6, 2013 Author Share Posted September 6, 2013 (edited) Sounds awesome dude, car looked great at the anniversary meet Thank you. The supercharger noises are more addictive than drugs. I'm looking forwards to completing the mechanical and electronic tinkering, I can then focus on the bodywork. Edited September 6, 2013 by David P (see edit history) Quote Link to comment Share on other sites More sharing options...
thetrashcanman Posted September 7, 2013 Share Posted September 7, 2013 Thank you. The supercharger noises are more addictive than drugs. I'm looking forwards to completing the mechanical and electronic tinkering, I can then focus on the bodywork. Haha they are, I'd love to a do a compound, supercharger and turbo charged supra, although not sure if that would even be possible. Quote Link to comment Share on other sites More sharing options...
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