Marty Posted November 24, 2006 Share Posted November 24, 2006 If the weather holds out there's no reason it won't be driveable by the end of the weekend. It just won't have any exhuast after the downpipe. Might take it for a drive anyway Like your style Quote Link to comment Share on other sites More sharing options...
Homer Posted November 25, 2006 Author Share Posted November 25, 2006 Despite the weather managed to get a few jobs done today, including fitting the turbo I forgot to mention this before the manifold install, but one more problem appeared, when test fitting the oil return, I found it hit the front support strut on the manifold. http://img143.imageshack.us/img143/8596/forum61cv0.th.jpg Support bar now removed http://img143.imageshack.us/img143/683/forum62cj1.th.jpg Now on with some of the jobs done today: Before the turbo could be fitted, the fitments for the oil and water lines need to go on it. 1) The male/male fittings for the water feed and return (M14x1.5, -8) 2) The oil feed fitting (-4 female/female) and -4/-3 adaptor). They're needed as the oil feed pipe is -3, but the oil restrictor on the turbo is -4. These were not included in the BL oil kit 3) The oil return fittings (Came as part of the BL oil kit) 4) The oil restrictor (Pre-installed by BL) http://img143.imageshack.us/img143/5374/forum58yg3.th.jpg Installing them is a 2 minute job http://img143.imageshack.us/img143/7602/image59hx3.th.jpg http://img143.imageshack.us/img143/8548/forum60ln0.th.jpg Quote Link to comment Share on other sites More sharing options...
rik Posted November 25, 2006 Share Posted November 25, 2006 Good work mate. I'm glad somebody had a productive day. Quote Link to comment Share on other sites More sharing options...
Homer Posted November 25, 2006 Author Share Posted November 25, 2006 A relatively simple job, I used the gasket supplied with the XS kit and some bolts I got from Halfords. The XS kit strangely didn't have any suitable bolts with it. Also, its worthwhile removing the compressor housing at the stage so the bolts can be reached. The two closest to the block have to be mounted the other way up as the exhaust housing doesn't allow a bolt to be inserted from above. http://img179.imageshack.us/img179/8210/forum63ym9.th.jpg http://img179.imageshack.us/img179/8776/forum64tc2.th.jpg Woohoo, turbo installed!! http://img142.imageshack.us/img142/3224/forum73kz1.th.jpg The oil return was a bit of a fiddle to install, its obviously designed for the clocked manifold which has the turbo position further away from the block. I had to dismantle one end of the fitting and trim around 1 inch of the braided line off. http://img143.imageshack.us/img143/9845/forum65pm2.th.jpg Next is to install the oil feed, the L fitting goes onto the restrictor, then the adaptor in the end http://img322.imageshack.us/img322/166/forum66bt0.th.jpg Then attach the oil line http://img322.imageshack.us/img322/3628/forum67er7.th.jpg Next up is the water feed. For those that haven't seen how the Aeroquip fittings work, a few pics: Here's the fitting split down: http://img322.imageshack.us/img322/1388/forum68tc0.th.jpg its as simple as pushing the pipe into the socket.... http://img322.imageshack.us/img322/5529/forum69yb4.th.jpg ...then pushing the main fitting in and tightening. Make sure the hose is being firmly gripped so that the threads bite into it. http://img120.imageshack.us/img120/9666/forum70oz3.th.jpg Now, it just screws on to the fitting installed on the turbo earlier http://img120.imageshack.us/img120/338/forum71ow7.th.jpg Quote Link to comment Share on other sites More sharing options...
Homer Posted November 25, 2006 Author Share Posted November 25, 2006 Damn 10 pics post limit!! The other end of the hose needs to be connected to the T-piece installed last week. http://img292.imageshack.us/img292/9636/forum72cz0.th.jpg That’s the water feed done. The water return is a real PITA so could take a day or two before that’s done... Quote Link to comment Share on other sites More sharing options...
Nic Posted November 25, 2006 Share Posted November 25, 2006 Darryl, I still need to order the oil, water lines and breather hoses, etc. Noticed you got the BL Oil line kit, where did you get the all the water lines and breathers/filters from? Did the BL oil kit include everything you needed? Quote Link to comment Share on other sites More sharing options...
Homer Posted November 25, 2006 Author Share Posted November 25, 2006 Darryl, I still need to order the oil, water lines and breather hoses, etc. Noticed you got the BL Oil line kit, where did you get the all the water lines and breathers/filters from? Did the BL oil kit include everything you needed? The BL kit contained all the oil feed and returns except: 1) The oil restrictor (Which should be supplied with the turbo) 2) The 90 degree adaptor for the oil feed - the shiny red and blue fitting posted earlier cost over £25!) For the breather system I'm replicating stock. The exhaust side cam cover one is being routed into the air intake using basic rubber braided hose and Aeroquip hose finishers (Basically Jubilee clips that look pretty ). The same applied for the IACV breather, its being routed back to the intake - though many use a K&N filter here instead (It sure is tidier!) The water lines are again basic rubber braided hose with Aeroquip connectors (Each connector is over £25!) I got all these fitting from Think Automotive (http://www.thinkauto.com), they're the main distributor for Mocal and Aeromotive products in the UK. Hope this helps Quote Link to comment Share on other sites More sharing options...
Ian C Posted November 26, 2006 Share Posted November 26, 2006 The oil restrictor is only needed for the DBB turbos. Plus you should find there is one integral to the bearing cartridge anyway so any fitting will do really. Glad to see you got the oil drain issue sorted out, that support bar getting in the way is interesting -Ian Quote Link to comment Share on other sites More sharing options...
Ulrik Posted November 26, 2006 Share Posted November 26, 2006 Nice work, now come and work on mine Quote Link to comment Share on other sites More sharing options...
Dragonball Posted November 26, 2006 Share Posted November 26, 2006 Thanks to some advice from MPryde, I think I'll try something else with the downpipe. Now going to try and find a long flexi pipe to weld on instead, this should allow a little more movement and make the fitment much easier Really good point there mate - reminded me - thanks! Should take the strain off the manifold a bit Nic - you might look at one of these for your downpipe and just get it fabricated Just when you do look at the flexi ends - some come up smaller than the pipe you are fitting them to i.e. a 4" diameter flexi end reduces the pipe down to 3.5 when fitted (if that makes sense) Good thread - well impressed with the input m8 Quote Link to comment Share on other sites More sharing options...
Homer Posted November 26, 2006 Author Share Posted November 26, 2006 Got a whole load of stuff done today, its getting very close to fire-up time First thing today was to change the water feed pipe I fitted yesterday, the T was in the wrong position (okay, it may not make much difference but I prefer the flow to be more direct to the turbo) : http://img50.imageshack.us/img50/1792/forum74vw7.th.jpg Water neck mod As the stock turbos are gone the water returns need to be blocked off. Normally, on a water cooled aftermarket turbo one of the stock returns is reused, however due to the position of the turbo on the XS power turbo there isn't enough space to get an a fitting in. Instead I've tapped a thread into the thickest part of the water elbow (even then it wasn't very thick at all!). This uses an M14x1.5 to -8 fitting. The stock returns are pulled out using a pair of pliers, then a thread tapped in (M10x1.25) and some chopped down bolts inserted (with lots of sealant and a couple of crush washers). The finished article - hope it doesn't leak! http://img231.imageshack.us/img231/7400/forum75bi3.th.jpg Reinstalled, be sure to replace the gasket as its not reusable http://img102.imageshack.us/img102/1101/forum76gq7.th.jpg Now the water return can be fitted. As mentioned yesterday, these pipes are simple to make up, though are very expensive. This bit alone cost £55! I would have preferred toi use push-on connectors at the water elbow, but there just isn't enough room, which is why I resorted to 90 degree fittings http://img63.imageshack.us/img63/1503/forum77mp0.th.jpg Another: http://img75.imageshack.us/img75/4906/forum78aj8.th.jpg IC pipe install I've had a real time getting this IC pipe to work out, its still not right but will do the job until I can get something better made. First fo all is to install the HKS SSQV. This is the some one I had installed before, but the mounting is different so have to take the BOV apart to remount it. This first pic shows the stock one split apart: http://img124.imageshack.us/img124/3189/forum80kj7.th.jpg Then the O-Ring has to be fitted to the new flange, the BOV inserted and the C clip fitted: http://img89.imageshack.us/img89/6163/forum82bl4.th.jpg Now its ready to install, just a simple matter of cutting some silicon hose down to size and fitting some jubilee clips: http://img144.imageshack.us/img144/9808/forum83bo0.th.jpg The fitment is not good and BOV will have to make do in its current position. This will change when a proper pipe is fitting// Reached the pic limit on this post so will continue in the next... Quote Link to comment Share on other sites More sharing options...
rik Posted November 26, 2006 Share Posted November 26, 2006 Nearly there now mate You gonna take it to a rwyb at Pod when it's done? I'll meet you there if you do. I'll have to take you on in my Audi though as the soops not done Quote Link to comment Share on other sites More sharing options...
Homer Posted November 26, 2006 Author Share Posted November 26, 2006 Now the IC and air intake pipe can be properly test fitted it turns out there is plenty of space for the boost controller solenoid on the front chassis rail. Just a side note - as you can see I had a bit of a surprise - body filler on the chassis leg... what’s going on there? This can't be normal... or a good sign http://img465.imageshack.us/img465/384/forum84ht4.th.jpg Next I needed to reroute the line from the rear of the wastegate. I had originally planned to route this over the back of the firewall, but can now route it the same way as the other one from the wastegate - under the engine mount and up near the alternator. Much tidier! http://img476.imageshack.us/img476/9200/forum85gm1.th.jpg Now the boost controller and wastegate install can be finalised. A mentioned previously, the side port on the wastegate needs to be attached to the OUT port on the boost controller. The end port on the wastegate needs to connect to the fitting on the compressor housing, but also needs to be T'd into the IN port on the boost controller. Hopefully the following image makes it clearer: http://img329.imageshack.us/img329/3308/forum86zv4.th.jpg Starting to look like spaghetti junction, but thankfully there's no more hoses to go in down there http://img454.imageshack.us/img454/2161/forum87ni7.th.jpg Now, the bit I've been looking forward too for some reason - the air intake install The pics I took of making up these parts are pretty boring so I will skip them, but here's a summary: - As this is an XS power manifold there is a issue with clearance with the water elbow, in order to move the intake slightly away from it I've used a 110 degree 4inch silicon hose - The metal part of the intake is the one that came with the XS power kit, though its had around 7 inches chopped off it (Maybe it designed for an externally mounted intake!!) - The filter is an AEM one, I've heard from several sources that the K&N ones are prone to tearing on the flange, the AEM is apparently less likely to suffer from this. Fitting is simple, just line everything up and tighten the clamps http://img356.imageshack.us/img356/1306/forum88bo7.th.jpg One issue did come up - there's no way I could route the IACV breather to the air intake, however after talking to a few people and a few hours searching have decided to put a filter on the IACV rather than route back to the intake. It appears to work well on cars of the same spec as mine. As a result i need to get another hole blocked off on the intake and source an IACV filter (Traders, where are you? ) Cam breather Nice and easy one this. Its just a case of cutting the pipe to length and fitting the Aeroquip hose finishers (Much nicer than jubilee clips!) http://img157.imageshack.us/img157/8088/forum89gw2.th.jpg Doubt I'll be doing much for a while as I need to source parts (IACV filter, MIG welder and a flexi join for the exhaust - if anyone knows where to get a 3 inch flexi joint please let me know!) Quote Link to comment Share on other sites More sharing options...
lambertpig Posted November 26, 2006 Share Posted November 26, 2006 coming along great . i get envious when you guys make this sort of work sound so easy to do, wish i had the mind set required. still i have lots of other qualities will post when i can think of them:( Quote Link to comment Share on other sites More sharing options...
Homer Posted November 30, 2006 Author Share Posted November 30, 2006 Well, its nearly there! There's a few more things done, but not worth writing up just yet. Have a few minor (but show-stopping) issues to sort out tomorrow (Thanks yet again to LeeT for the help!). However I hope to fire it up sometime Saturday For now, I'll stick up the parts list that many people have been asking for. This contains EVERY part used, their price and the place purchased. There's probably one or two bits I've missed, but will update this list as I remember! Its Excel format, if anyone has problems reading it let me know and I'll put a text version upSupra single costs.xls Quote Link to comment Share on other sites More sharing options...
mikeyb10supra Posted November 30, 2006 Share Posted November 30, 2006 Well, its nearly there! There's a few more things done, but not worth writing up just yet. Have a few minor (but show-stopping) issues to sort out tomorrow (Thanks yet again to LeeT for the help!). However I hope to fire it up sometime Saturday For now, I'll stick up the parts list that many people have been asking for. This contains EVERY part used, their price and the place purchased. There's probably one or two bits I've missed, but will update this list as I remember! Its Excel format, if anyone has problems reading it let me know and I'll put a text version up Glad to see its all going ok Homer....bet your getting excited now that Excel list is a really handy as well....should maybe be saved as a permanent somewhere Quote Link to comment Share on other sites More sharing options...
RobSheffield Posted November 30, 2006 Share Posted November 30, 2006 Was just thinking that too, that needs stickying or putting into he downloads section. Quote Link to comment Share on other sites More sharing options...
Homer Posted December 1, 2006 Author Share Posted December 1, 2006 It's almost ready to fire up Its been a frustrating week, mostly waiting for parts to arrive or for time at the welders. Finally got the downpipe welded up today. It's now sporting a new flexi section which should take some pressure off the manifold/turbo and help absorb any vibration or small knocks to the exhaust. http://img170.imageshack.us/img170/2537/forum91yf5.th.jpg The exhaust was then wrapped and the O2 sensor fitted. Made a bit of a mess of this (Its more difficult than it looks!) and I didn't buy enough wrap to do it all - 6meters is required at least!. Will have to redo this at a later stage, for now it'll do. http://img177.imageshack.us/img177/1728/forum92jl1.th.jpg Then its just a case of fitting it. The XS V band is a rather poor quality and I'm worried about striping the thread when tightening. Have done it fairly tight for now, will have to see if it leaks tomorrow... Will buy a decent one later. Also fitted the turbo blanket (needs tidying up - another jpb for tomorrow!) http://img466.imageshack.us/img466/4582/forum96fp7.th.jpg Also sorted out the various boost sensors and IACV breather pipe today. In the pic below, '1' is the IACV breather pipe. I'm venting this to atmosphere rather than put a pipe all the way to the intake. The cam breather is already routed there so can't see why this one needs to go there too. '2' is a pressure pipe which I think used to go to the BOV, I'm going to be keeping this and using it for the same purpose (The main IACV pipe has to be cut off as its welded to the smaller pressure pipe) http://img177.imageshack.us/img177/6670/forum90rd1.th.jpg The IACV pipe can be cut short and reused, the tiny K&N filter just pops in the end of it. http://img357.imageshack.us/img357/2876/forum93yc4.th.jpg Next is to sort out the mass of pipes that need to connect to the various sensors. Rather than reuse the fpr pressure pipe (which I do not want coming loose (again!), I'll reuse the pipe that used to go to the pressure tank. http://img98.imageshack.us/img98/531/forum94xa1.th.jpg The following need to be a pressure feed on my setup: - Emanage pressure sensor (1) - Boost controller pressure sensor (2) - Boost gauge (3) I couldn't find a tidy way to plumb these together so just Tee'd the lot into the above mentioned pipe. Really need to get a vacuum plenum - anyone know who sells them? http://img178.imageshack.us/img178/7336/forum95pq7.th.jpg Also had a bit of a problem with the water elbow, I thought the o-ring on from the water pump was still in place, but it turns out it went missing at some point, hence refitting the neck and loosing a few litres of coolant after filling Toyota don’t stock them but managed to find a suitable replacement from Halfords. After refilling it seems to be okay, but the large M14 adaptor for the water return is leaking ever so slightly. Think I'm going to have to have this remade soon with a thicker alu piece welded in to get a decent thread into. Looking forward to tomorrow now! Quote Link to comment Share on other sites More sharing options...
terribleturner Posted December 1, 2006 Share Posted December 1, 2006 Cool So you'll be driving about Monday then Quote Link to comment Share on other sites More sharing options...
Guest blueangel Posted December 1, 2006 Share Posted December 1, 2006 looks very impressive good on ya fella Quote Link to comment Share on other sites More sharing options...
mr lover Posted December 1, 2006 Share Posted December 1, 2006 i think you should post up a sound clip Darryl of it firing up for the first time Quote Link to comment Share on other sites More sharing options...
Homer Posted December 1, 2006 Author Share Posted December 1, 2006 Cool So you'll be driving about Monday then Hopefully - provided nothing more starts leaking I won;t be driving very fast as it's still on the 440's! Quote Link to comment Share on other sites More sharing options...
Homer Posted December 1, 2006 Author Share Posted December 1, 2006 i think you should post up a sound clip Darryl of it firing up for the first time Would love to, but don't have a video camera... actually, might as well go and buy one! Quote Link to comment Share on other sites More sharing options...
MR.B Posted December 1, 2006 Share Posted December 1, 2006 Congratulations bud glad you're nearly sorted - looking good Quote Link to comment Share on other sites More sharing options...
Homer Posted December 1, 2006 Author Share Posted December 1, 2006 BTW guys, what do you do with these wires - are they safe to just cut off back under the cam cover? (I know you already said cut them off James, but want a 2nd opinion ) http://img472.imageshack.us/img472/4479/forum97op3.th.jpg Quote Link to comment Share on other sites More sharing options...
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