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#41 Androo26

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Posted 29 January 2014 - 04:32 PM

Knocked up this little adaptor flange today. Turbo boost pressure outlet . From 1 1/2" to 2" cold side piping.

 

IMAG1052_zpse84d06b4.jpg

 

IMAG1057_zps707eb371.jpg

 

IMAG1054_zps3e337101.jpg


Edited by Androo26, 29 January 2014 - 04:34 PM.


#42 Androo26

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Posted 30 January 2014 - 05:41 PM

Right now im happier than 7 pigs in mud !!!!!

 

In this thread about distributors......

 

http://austarletclub.com/index.php?/topic/19660-different-distributors/ 

 

I was after a dizzy out of a 5efhe ot a 4efte . So basically to replace my 4 toothed pickup from my stock 4efe.

 

Why all the fuss ? Well in order to run the Microtech LT9-C i want to use, I needed the distributor with the 24 tooth pickup.

 

With this distributor I can now run 4 LS1 coil packs and also run the fuel injection in full sequential operation and take advantage of individual cylinder trim functions ect.

 

So the story goes...... I ring at least 20 so called Import wreckers and 1 guy has a 4efte dizzy "yeah mate 220 !! " he says. Way too much for my liking.

 

After searching for days on the net for one I go down to the local wreckers and ask as I had nothing to loose. Low and behold old mate has 3!!! of them in a box out the back all from a Toyota Sera.

 

"175" he says. Bargain him down to 125 and then told him "ill have 2 at 100 each" and we do the deal, so now I have 1 and a backup one WOOHOO!!!

 

IMAG1061_zps62c86049.jpg

 

Also got the plug from a mid 90s 4 cyl Camry 3sge I think.

 

IMAG1062_zps181d4007.jpg

Note 24 tooth pickup.

 

And it fits like a glove.

 

IMAG1063_zpsbfbc7ee8.jpg


Edited by Androo26, 30 January 2014 - 06:02 PM.


#43 Androo26

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Posted 31 January 2014 - 07:04 PM

Since I wont be needing the dizzy cap on this one...... I have started to make a fancy cover to replace the cap.

I think ill end up painting it black.

 

 



#44 Androo26

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Posted 01 February 2014 - 09:24 AM

All finished and painted stealth black. I reckon its come up a treat !!

 

 



#45 Androo26

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Posted 02 February 2014 - 06:22 PM

A bit more progress, Almost finished the cold side cooler pipe Tig welded it all the way round on the joins, Just the final fitment and a lip to be put on each end.

 

IMAG1072_zps2cd08383.jpg

 

Also Ive made the flange for the external wastgate. Starts out as a bit of mild steel flat bar. (trace the gasket onto it. center punch and drill the 2 outer holes and hole saw the middle.

 

IMAG1069_zpsa4b9e2b3.jpg

 

Then cut the edges out with a cutoff wheel and grinder and de-burr the holes, bit of a sand and its done.

 

IMAG1070_zpsba9eeb1c.jpg


Edited by Androo26, 02 February 2014 - 06:23 PM.


#46 Graham

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Posted 02 February 2014 - 09:22 PM

You make it sound soo easy. How long did that take you? :)

#47 Androo26

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Posted 03 February 2014 - 06:26 AM

The welding or the flange ?

 

Welding bout and hour and a half. Flange maybe half an hour.

 

And yes I know you can buy them pre made. But I make stuff because I can.

 

And to show others what you can achieve at home with some know how and a few tools.



#48 Androo26

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Posted 03 February 2014 - 11:20 AM

Ive decided to re-mount the intercooler as I wasnt completly happy with the mounting position. (too far forward at the bottom).

 

So now its on an angle and hopefully be able to scoop up a bit more fresh air stream.

 

IMAG1074_zpsc550db13.jpg

 

IMAG1077_zps8e951cc6.jpg

 

The brackets at the bottom of the cooler have nowhere to bolt up to. So my solution is to weld in some threaded mounting plates.

 

I started by marking, center punching and drilling the brackets then drill through the brackets onto the framework where i want the center of the threads to be and, next I got me a Step Drill

 

IMAG1080_zps9b9a17da.jpg

 

The hole on the right is a bit higher beacause of the already existing hole, just drilled out.

 

IMAG1081_zps81ac40d5.jpg

 

What is a step drill youa ask ?? Its a drill for drilling sheet metal (much better than an ordinary drill) These can be brought from Bunnings.

 

IMAG1082_zps29d0410f.jpg

 

IMAG1084_zps5e6a1190.jpg

 

These little plates will have a nut each welded onto them making the threaded plate. Next the plate will be welded to the frame with the nut facing in. Nice and neat ., and will paint over the top also.

 

IMAG1085_zpsbe96a3e3.jpg


Edited by Androo26, 03 February 2014 - 02:44 PM.


#49 Androo26

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Posted 03 February 2014 - 02:42 PM

The nut has been welded on each side to both brackets and setup ready for installation.

 

 



#50 Androo26

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Posted 04 February 2014 - 06:00 PM

Got a little more completed today. Welding of the threaded intercooler supports into the frame.

 

 

 

 

Then a couple of coats of Galmet Paint . Green in colour.

 

 

This will all be covered by the front bar so its not critical that its not quite the same colour.



#51 Androo26

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Posted 04 February 2014 - 06:05 PM

I will share a trade secret that ive been using for a while and that is "how do you weld a nut central to the hole" ?

 

Well you can drill the hole size out 1mm oversize here and use a countersunk bolt like so...

 

IMAG1092_zps8139a26c.jpg

 

IMAG1091_zps311ca82e.jpg

 

The taper of the bolt centralises the nut to the hole . Quite simple really....

 

[url=http://s1217.photobucket.com/user/Androo261/media/IMAG1093_zpsaf554c1d.jpg.html]IMAG1093_zpsaf554c1d.jpg[

 

 

Ready to weld !!!


Edited by Androo26, 04 February 2014 - 06:06 PM.


#52 -Harry-

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Posted 04 February 2014 - 08:28 PM

Love the attention to detail. Kepp it up with the details, always an interesting read.

 

I'd love to be able to tig weld. Fearless even bought a 3 phase mig recently but none of us can use it. What do you do for a living? The tig welds on the cooler piping look perfect.

 

We use Nutserts on the race cars. Drill a hole and use like a rivet. Works in any material too. No where near the strength of what you've done there though.

527763570_o.jpg

 

Beadlock2-3.jpg


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#53 Androo26

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Posted 04 February 2014 - 09:08 PM

Well Harry glad you asked, im currently a Fitter/ Machinest at a manufacturing factory and also also have a Trade certificate in Automotive light vehicles (Mechanic) .

 

Guess it helps that I have a full engineering shop as my work place..... but try to do most stuff at home.

 

We have those nutsert things at work also .. im not really a fan as ive seen too many times they spin when undooing them instead of gripping properly. Maybe if it spot welded itself to the material itd work better....

 

As far as tig welding goes its all practice..... not really too hard to pick up though.

 

This guys tig welding makes a mockery of anyhting ive ever done....

 

219.jpg

 

http://www.shaunscustomalloy.com.au/  Check this stuff out Brilliant!!!


Edited by Androo26, 05 February 2014 - 07:49 PM.


#54 Androo26

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Posted 05 February 2014 - 05:08 PM

In the mail today was this !!!

 

 

And these LS1 Coils

 

IMAG1105_zps35cbc16d.jpg

 

Also today i finalised the mounting of the cooler. Its really rigid now as it has 6mm flat bar lower brackets

 

[url=http://s1217.photobucket.com/user/Androo261/media/IMAG1107_zpsc9ea53d9.jpg.html]IMAG1107_zpsc9ea53d9.jpg


Edited by Androo26, 05 February 2014 - 08:00 PM.


#55 Androo26

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Posted 05 February 2014 - 06:14 PM

just wanted to show a more detailed pic of the top cooler/ bonnet catch support.

 

 

Also my fancy battery holder

 



#56 Androo26

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Posted 06 February 2014 - 03:41 PM

A start on the coil holding bracket

 

 

These steel steam pipe bends turned up today also. 10 long raidius 10 short radius.  $65.00

 



#57 Androo26

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Posted 08 February 2014 - 07:34 AM

 The coil packs will be mounted in this position.

 

8db083c2-73c5-46e1-9532-9cdd9bd2b353_zps


Edited by Androo26, 08 February 2014 - 07:36 AM.


#58 Androo26

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Posted 10 February 2014 - 10:41 AM

After being stuffed around by a seller of turbo collectors I still havnt got one .... so im going to make my own one up.

 

I have a Makita dropsaw for timber use , that I have engineered a jig for to cut the angles I need. I got a metal cut off wheel for it from bunnings aswel.

 

 

 

 

 

The cutting angle has been set at 15 degrees so a combined angle of 30 degrees when welded together.

 

This is as far as Ive gotten so far... Pretty impressed with how it is so far.



#59 Androo26

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Posted 10 February 2014 - 01:05 PM

And a bit more.

 



#60 Errday91

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Posted 11 February 2014 - 02:40 PM

^^ that's cool :) came out really well.

 

 

I noticed your goal is 160kw atw. what are you doing to the engine internals?






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