Ulrik Posted November 8, 2006 Share Posted November 8, 2006 Looking good Keep up the good work Quote Link to comment Share on other sites More sharing options...
silvershark44 Posted November 8, 2006 Share Posted November 8, 2006 I would love to try this someday, but wouldnt know where to start! Quote Link to comment Share on other sites More sharing options...
Homer Posted November 8, 2006 Author Share Posted November 8, 2006 Thanks for the support guys! Now it is time to test fit the manifold, wastegate, screamer pipe, turbo and downpipe. I did it in stages to save cluttering things up too much. First up is to fit the manifold. As you can see it did not fit straight on as the holes didn't line up properly with the studs. http://img300.imageshack.us/img300/9753/forum11xe4.th.jpg There were 5 holes in total that needed some material grinding out with a Dremel. They weren't drastically out, the worse only needed 0.5mm removing. Next is to check stud clearance, as with almost all manifold, one stud fouls on on the no4 runner. http://img296.imageshack.us/img296/4501/forum12pk0.th.jpg I took the cheap and easy way out and cut the stud, most professionals would replace the stud with a shortened one. http://img69.imageshack.us/img69/6451/forum13px3.th.jpg The manifold now fits http://img69.imageshack.us/img69/5808/forum14gn3.th.jpg Next is test fitting the wastegate and screamer pipe. The good news was the wastegate fits fine, the bad news is the screamer pipe doesn't. I had always had doubts about the angle the pipe exits but the test fit confirmed its out by quite some margin. The picture doesn't show it very well, but the pipe hits the 1st cat heat shield and is obvious pointing at a less than optimal place! Obviously I need to get the flange off and rotate it around 25deg. http://img299.imageshack.us/img299/8955/forum15pd9.th.jpg The next pic shows the current position and where it needs to be adjusted to http://img359.imageshack.us/img359/9355/forum16cg7.th.jpg Next up is to check the turbo install. Now I knew this was going to a be a problem for some time as several people have warned about the BL turbo's not fitting on the XS Power manifolds. The BL turbo has a much larger compressor housing than the XS Power turbo's the manifold was designed for, as such the housing fouls on the no1 runner. http://img299.imageshack.us/img299/2513/forum17pj9.th.jpg Some people have previously commented that the BL (Precision)turbo fouls on the support bar and/or cam cover. The following picture shows its close to the bar, but does not touch it (Okay it looks like it touches in the pic but that but is about 6mm above the bar) http://img476.imageshack.us/img476/6352/forum18nc0.th.jpg Quote Link to comment Share on other sites More sharing options...
Homer Posted November 8, 2006 Author Share Posted November 8, 2006 Okay, so clearly there's a major problem with the turbo fitments. There's two ways to work around this: relocate the T4 flange on the manifold to a 'clocked' position (like most of the premium ones), or use a spacer. Again I'm taking the easy option and using a spacer. Using some aerospace quality cardboard I've worked out approximately how much the turbo needs to be raised to clear the runner - its a lot - 20mm! The clearance from the runner with this size space is still tight, at only 3-4mm on the elbow weld. I was thinking about using a small 1inch wide section of heat wrap on this runner, but think this may create a hot spot on the pipe and cause the weld to crack... thoughts anyone? http://img292.imageshack.us/img292/533/forum19wg8.th.jpg The downpipe is the final thing to check and how wrong was I about this fitting! For some bizarre reason the kit from XS Power contains a downpipe for a clocked manifold, which will obviously never fit the one in the kit! Not only is the angle wrong, but its also far too short. I suspect they've copied this from a premium brand one where the turbo is mounted slightly more towards the rear of the engine bay. http://img67.imageshack.us/img67/3635/forum20cx3.th.jpg So, tomorrow I'm off to a local fabrication company to get some parts made up and others adapted. Just hope I got the measurements correct! Quote Link to comment Share on other sites More sharing options...
Miguel Posted November 8, 2006 Share Posted November 8, 2006 Bit of a starnge place where the screamer pipes exits. does it not turn round and go like this one ? Quote Link to comment Share on other sites More sharing options...
jazz1 Posted November 8, 2006 Share Posted November 8, 2006 nice to know what ur doing, are you a mechanic? Quote Link to comment Share on other sites More sharing options...
Homer Posted November 8, 2006 Author Share Posted November 8, 2006 Got a bit fed up with the fitment problems on the XS Power kit so decided to fit some of the oil feed/return kit. In the pic below is shows: 1) The blanking plug thats used to be the feed for turbo #2 2) The adaptor for the oil feed (used to feed turbo #1) 3) The oil return. Unlike many kits the BL one came with a 40deg adaptor to move angle the pipe away from the steering rack bolt. The pipe fits straight on http://img518.imageshack.us/img518/9809/forum21hq1.th.jpg Thats all for today. Hopefully will have some metalwork done tomorrow. Also, hurry up Scooby and with those parts! Quote Link to comment Share on other sites More sharing options...
mr lover Posted November 8, 2006 Share Posted November 8, 2006 looking good darryl, be intresting to see it completed and taken for a spin Quote Link to comment Share on other sites More sharing options...
Homer Posted November 8, 2006 Author Share Posted November 8, 2006 Bit of a starnge place where the screamer pipes exits. does it not turn round and go like this one ? Unfortunately not, it points directly into the subframe with it rotated Also, as the wastegate flange fitting is rectangular, it can't be rotated so the pipe runs underneath it. nice to know what ur doing, are you a mechanic? Lol, I don't know what I'm doing really, just following advice of those that have done this before. Also I'm certainly no mechanic! IT's more my sort of thing Quote Link to comment Share on other sites More sharing options...
Miguel Posted November 8, 2006 Share Posted November 8, 2006 Poo. Cool write up tho, keep up the good work Quote Link to comment Share on other sites More sharing options...
rik Posted November 8, 2006 Share Posted November 8, 2006 Looking good Darryl. This thread could come in very handy later. You'll have to take me for another spin next time we meet, so i can see the difference Quote Link to comment Share on other sites More sharing options...
jazz1 Posted November 8, 2006 Share Posted November 8, 2006 well good work mate and good luck Quote Link to comment Share on other sites More sharing options...
Bobbeh Posted November 8, 2006 Share Posted November 8, 2006 Yeah, all the bst with your project Darryl, and when you're successfull with this one you can do mine! Just remember to keep the noise down Quote Link to comment Share on other sites More sharing options...
johnd-mkiv Posted November 8, 2006 Share Posted November 8, 2006 Great thread mate will look forward to the out come;) Quote Link to comment Share on other sites More sharing options...
terribleturner Posted November 8, 2006 Share Posted November 8, 2006 Bit of a starnge place where the screamer pipes exits. does it not turn round and go like this one ? I was going to say the same thing. Daryll why not cut it down?? It is very long already Quote Link to comment Share on other sites More sharing options...
Homer Posted November 8, 2006 Author Share Posted November 8, 2006 I was going to say the same thing. Daryll why not cut it down?? It is very long already That was my first thought, but due to the position it would mean venting exhaust gas into the engine bay (plus gasses pointing directly into the firewall. Not a good idea - I don't want to be poisoned Or, did you mean using the vertical position mig posted? The pipe points directly into the subframe so even chopping it down will result in gasses flowing directly into it. I'll try and get some daylight pics tomorrow and show the positioning Quote Link to comment Share on other sites More sharing options...
Ian C Posted November 8, 2006 Share Posted November 8, 2006 The BL kit has the screamer pipe exiting as attached, I guess your setup doesn't point at the same place? -Ian Quote Link to comment Share on other sites More sharing options...
Homer Posted November 9, 2006 Author Share Posted November 9, 2006 The BL kit has the screamer pipe exiting as attached, I guess your setup doesn't point at the same place? -Ian Oh right, after looking at yours and Migs pics in more detail I'm not sure anymore! The only XS power kit I looked at in detail was LeeT's where the pipe exited alongside the downpipe. Though I'm sure the downpipe pointed directly into the subframe I'll try the fitting again tomorrow in better light and take some pictures. Thanks for the input chaps Quote Link to comment Share on other sites More sharing options...
Homer Posted November 9, 2006 Author Share Posted November 9, 2006 Just a thought Ian/Mig, is this more like it looks fitted? I think its not pointing down enough to clear the subframe: http://img375.imageshack.us/img375/5779/fourm22bf4.th.jpg Quote Link to comment Share on other sites More sharing options...
terribleturner Posted November 9, 2006 Share Posted November 9, 2006 Yeah that's the right way. Quote Link to comment Share on other sites More sharing options...
Homer Posted November 9, 2006 Author Share Posted November 9, 2006 Yeah that's the right way. Ooooh, right... I'm starting to feel a little stupid, but thats not a new feeling I guess I have to chop a little off the end? BTW, did you manage to post that fitting yesterday James Quote Link to comment Share on other sites More sharing options...
adi2009 Posted November 9, 2006 Share Posted November 9, 2006 What blow off valve are you using mate? XS? Quote Link to comment Share on other sites More sharing options...
terribleturner Posted November 9, 2006 Share Posted November 9, 2006 Ooooh, right... I'm starting to feel a little stupid, but thats not a new feeling I guess I have to chop a little off the end? BTW, did you manage to post that fitting yesterday James Yeah gave it to my old man to slip in with the work post Quote Link to comment Share on other sites More sharing options...
Homer Posted November 9, 2006 Author Share Posted November 9, 2006 As suggested I've tried the sreamer pipe in the down position in the daylight, but theres no way it will fit. In the picture the manifold is about 1 inch too high, if I cut the tube down its still going to point directly into the cross member. http://img84.imageshack.us/img84/9954/forum22xs5.th.jpg Also visited 5 different fabricators today to find someone who can modify the down pipe, after 2 hours of walking around Reading found a place called Higgins engineering that will do the work. Thankfully they can also make the T4 spacer and adjust the screamer pipe. Unforutnalty they won't be ready until mid next week, so the build is going to have to stop for a few days Quote Link to comment Share on other sites More sharing options...
Homer Posted November 9, 2006 Author Share Posted November 9, 2006 What blow off valve are you using mate? XS? I've reusing the HKS SSQV which I already had, though the stock adaptor needs to be removed and a new flange fitted to the IC pipe. Yeah gave it to my old man to slip in with the work post Thanks fella! Quote Link to comment Share on other sites More sharing options...
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