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 Boostn
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| posted on March 10th, 2009 at 03:23 PM |
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I'd stick with the messa / fan combo.
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humpty
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| posted on March 10th, 2009 at 09:19 PM |
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It has internal fins also, but I have no clue to its efficiency...
It's theory is solid (heat sink), but its practice is unknown...
Spose it's better to be safe than sorry....
Off to ebay I go... Hi ho, hi ho.....
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Stanley
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| posted on March 11th, 2009 at 09:07 AM |
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Also important to remember is the pressure required to force oil through the cooler.
Coolers are also a great place for debris to end up. The easier it is to flush the better it is.
Seen many hydraulic systems fail multiple times when people couldn't clean or wouldn't replace coolers.
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humpty
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| posted on March 22nd, 2009 at 08:26 PM |
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Hey gang... Got another question for the guru's out there!.... That of O2 Sensor placement.
For those of you that don't remember (or know), the POS is being built to compete in the local Nostalgia Drag series (Streetcar) and for this reason
I have gone with an ol'school configuration...
Draw-through.... (ie: NoTech!  )
The turbo has been changed for a GT28R but the system is mostly the same. I have now also fitted a V-Band Clamp about 100mm down stream from the dump,
just before the bend in the exhaust...
Anyway... To make the old girl a little easier to tune I have been permitted to fit an O2 sensor, but my issue is the placement of it... I was
thinking about where the arrow is, just before the V-Band Clamp so as not to upset the whole lot when I do the change at the track from the street
zorst to the race dump...
What you all think? Could there be an issue with the O2 being so close to the turbo?
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Boostn
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| posted on March 23rd, 2009 at 03:22 PM |
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no
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Stanley
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| posted on March 23rd, 2009 at 03:59 PM |
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From research i've done on this stuff before that is pretty much the location of choice.
now hurry up and get it done...
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humpty
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| posted on March 23rd, 2009 at 05:42 PM |
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| Quote: | Originally
posted by Boostn
no
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Cheers...
| Quote: | Originally
posted by Stanley
...now hurry up and get it done...
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I have about an hour a week to work on the old girl, so you can understand my frustration...
And my lack of motivation at times...
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Boostn
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| posted on March 23rd, 2009 at 07:16 PM |
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sleep is over rated
weld the bung in
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humpty
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| posted on March 23rd, 2009 at 07:44 PM |
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Hole is drilled... Off to the TIG tomorrow...
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humpty
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| posted on April 8th, 2009 at 12:08 AM |
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Finally got in touch with my TIG dude... All done to the dump manifold... Mocked up the dump down tube today and it looks pretty good... Only MIG
tacked at the moment... Will give a final touch-up once the engine is back in the car....
Pics to follow as soon as my shaped account sorts itself out.... 
Trimmed the 'T' manifold today and that slots in nice, though I need to clearance the cross-pipe under the alt mount... Will tack the manifold to
turbo flange tomorrow.... Start on making the carb support in the next day or so.... Then its time to match port the VW end-castings to the head
ports....
And now I have a question...
I need to find a suitable boost signal for the built-in wastegate... Turbo does not have one on the compressor side....
Should I put a fitting in the manifold just after the turbo outlet or can I use the boss that is in the LHS end-casting? The MSD will need a signal
from here too!!
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Boostn
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| posted on April 8th, 2009 at 12:27 AM |
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I run a balance hose from side to side and tee off in the middle. This way it stops cylinder pulsing in the signal.
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Stanley
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| posted on April 8th, 2009 at 07:13 AM |
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Mine had a boss on the compressor side that had not been drilled. I drilled and tapped it 1/8 npt an run a signal to WG from there. Yours may or may
not have one. Otherwise Nicks fix sounds good.
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humpty
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| posted on April 8th, 2009 at 09:13 AM |
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Cheers guys....
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humpty
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| posted on April 13th, 2009 at 08:43 PM |
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Finally got my camera from school...
So I took some pics today of the engine progress to date... this should give you some idea...
It's slow work this Stainless Steel fabrication... Of course it doesn't help that I don't get much time on it... Will be doing some more on
Wednesday... Fuel system and trans mounts are planned for then... Then the engine goes back in and final exhaust/muffler arrangement can be fabbed
up...
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humpty
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| posted on April 21st, 2009 at 12:59 AM |
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Bit more done today... Made some shock plates and T1- TIII beam adapter mounts for a mate and got a little more done on the POS....
Here's a little comparo.
As it was.....
As it is.....
When you compare it to how the old IHI set-up was, I think this is a much better fit...
As the carb is now solid mounted to the turbo I need to figure out if I need to make a carb support...
What you all reckon?
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Stanley
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| posted on April 21st, 2009 at 06:43 AM |
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Good stuff...
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pete wood
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| posted on April 23rd, 2009 at 10:45 AM |
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| Quote: | What you all reckon?
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I reckon I'm jealous and your back tyres should be feeling scared.
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humpty
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| posted on September 3rd, 2009 at 07:38 PM |
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Ok.... After finally getting back to the POS for some little "one'on'one", I have managed to get some more stuff completed....
First up.... Fuel system....
Holley Blue and Chrysler 300 fuel filter...
Dual 10mm ID fuel line hand formed from the front...
To the rear...
Peaking out over the torsion housing...
Then soft line to still more hand formed hardline...
Across the car under the parcel shelf...
Through the rear firewall panel to the regulator...
Just remember... This is version 4 of my fuel system.... I seem to do that.... Start off conservative, build on it, do more research, make some
changes, ask more questions, make yet more changes, then finally complete it....
For now....
Then the fancy new aluminum solid trans mounts (from A 1200 is slow) went in along with a set of Craig Torrens' "K" bar kits.... Kindly sold to me
for an awesome price.... I would like to say that both of these products are top shelf and would recommended them to anybody...
Cheers fellas!...
And then the engine went in for little checking of clearances...
Tight! 
But she's in!...
Apron on....
And I'm back to were I was 12months ago....
But hopefully it's a little more solid now....
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reub
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| posted on September 3rd, 2009 at 08:23 PM |
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Cool as Simon. Really good to see some progress.
Trust all is well down there! Reub
Reub
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humpty
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| posted on September 30th, 2009 at 10:06 PM |
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The holidays are here!.....
So what have I been upto I hear you ask?
Heaps....
First up, I have decided to not run a dizzy on this engine, as I feel that method of spark is erratic and hard to control... You need a really good,
solid and consistent spark on forced induction engines, so I have gone down the EDIS/Megajolt road and have pulled the 09 out for good... So I need to
plug that bloody great hole up left behind by the dizzy... So I made this on Monday...
Fits a treat and uses the OEM clamp and 'O' ring too... Might convert it to a cranckcase breather/drain later...
The I had to finish off the intake manifold and endcastings... So I pulled out the airtools did a spot of die grinding and match porting... But I had
to make a template of the heads first...
Bit of a difference hey?
Then the fun begins...
Then I had a go at the other end.... Had to match up with the new "T" centre manifold I made earlier this year....
The it was time for the exhaust... Mock-up to make sure it all fits....
I taped it all together, then took it to school and tacked it... Brought it back home and fitted it.... And it's perfect.... So I then took it over
to my mate Dave to get it TIG'ed up... And here she it is.... Finished!
And on the car...
Pretty huh?
Today I made the carb support (and cool little press jig to radius the ends of the tube I used), the accelerator return spring bracket and cable
support, fitted a bigger breather in the tank, fitted the fuel return to the tank, fitted the tank, reset the rear spring plates and started on
fitting the rear brakes, started on making the springplate retainers/limiters, and made a tailpipe support too....
Gotta do some more work on the ignition tomorrow... Have to make a whole new harness for it, fabricate a mounting block for the Megajolt and EDIS
computers and relays... And loads of other little things...
Getting closer!
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on October 1st, 2009 at 05:17 AM |
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Spiff!
Cant wait to see what the details are to trigger your new ignition Simon.
| Quote: | Originally
posted by westi
That's mad Alan.
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Stanley
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| posted on October 1st, 2009 at 06:36 AM |
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Nice work Humpty...exhaust looks good
I'm with dave....more info on the ignition setup please.
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colonel mustard
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| posted on October 1st, 2009 at 12:08 PM |
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I love the "muffler".... what sort of Motorbike did you 'borrow' that one off...  Love it man. its gonna be sick!
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humpty
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| posted on October 14th, 2009 at 11:11 PM |
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The latest...
Made this to support the DCOE.... It supports the carb over the top and bolts to the back of the turbine housing...
Then I started on adapting the EDIS Ignition timing wheel to the Stoker Engineering Pulley that Dave made for me years ago...
This to this...
Get a little bit of wood...
Screw this on...
Whack it on a wood turning lathe and hey presto!.... An adapter that centrally locates the timing wheel to the pulley...
Line it up, clamp it down, drill it out, then tap in some nice little M3 threads...
Tah Dah!
And yes I know the BERG timing ring label is 180º out!!!
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hellbugged
A.k.a.: Daimo Pell
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| posted on October 15th, 2009 at 07:59 AM |
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| Quote: | Originally
posted by humpty
And yes I know the BERG timing ring label is 180º out!!!
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very nice happenings humpty.......
you want a new ring sent over?
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humpty
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| posted on October 15th, 2009 at 09:49 AM |
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| Quote: | Originally
posted by hellbugged
| Quote: | Originally
posted by humpty
And yes I know the BERG timing ring label is 180º out!!!
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very nice happenings humpty.......
you want a new ring sent over?
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Yeah I reckon thats a good idea.... I've been putting up with this one since the old Hellbug days... Good times....
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humpty
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| posted on October 26th, 2009 at 09:14 PM |
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Next question....
I'm looking at external oil cooler options again...
This thing I've been messing with has been built to compete in the local nostalgia drag series... This baby is old school all the way, but the rules
allow for a few 'common sense' upgrades as the cars must be street registered to compete... So I have a few contemporary upgrades on board...
To help the little bundle of joy keep it's head in the hot West Oz sun, I'd like to plumb in another cooler after the OBerg.... I have a doghouse
cooler in place, but I feel this will not be up to the task... What are the guru's of AVD doing about this situation?
Cooler (brand, size etc), inline thermostat (MOCAL, electronic), OG thermostat upgrade, by-pass, placement, fan... Any other ideas?
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humpty
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| posted on November 2nd, 2009 at 09:18 PM |
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Here's a shot of the ignition bits I am cobbling together.... I'm using a US/UK/Euro market FoMoCo EDIS iginition driven by a Megajolt
computer...
The EDIS stuff I bought from Boost Engineering ( http://www.boostengineering.net/ ) in the US and the Megajolt is a kit I bought from Autosport Labs ( http://www.autosportlabs.net )... The kit was pretty straight forward to assemble...
2-3 hours with a soldering iron is all it took... The of course was getting the rest of the stuff sorted.... I had to make a harness for it all and a
suitable mounting dock to...
So out came the old Subaru harness' I have kept...
4 hours later I had found the right colour and gauge wires to make it all happen.
Then its back to a spot of fabrication.... Here's the bracket I told you about... Need a little tidying up, but it works well enough, and it has a
small amount of adjustment in it....
Then I had to get on to the plug leads.... The leads I got from the US would have worked, but it meant I would have to run the coil pack in the centre
of the firewall... It's an ugly bit of kit, so I decided I needed to hide as best I could... To do this I needed to source some new plug leads....
After trying everywhere for the past 2 weeks I resigned myself to either import some, or make some.... Being the cheap arse that I am, I made
them...
Found some very nice aftermarket leads off a late model V8 Falcon and promptly cut the coil end off and fitted the EDIS ends... It took a bit of
fiddling to salvage the covers and copper fittings without damaging them, with a little silicone spray, some fine flat blade screwdrivers and needle
nose plier, the job got done...
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humpty
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| posted on November 25th, 2009 at 10:35 PM |
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Well gang.... I have some good news and I have some bad news.....
The good news is I got it running on Monday night for the first time.... After a few problems with the ignition, I figured out the issue and she fired
right up.... A little smokey but good.... Today I had some time this arvo to have a fiddle with the ignition map and get it running a little
smoother.... It certainly has a big strong note!!!
Now for the bad news... The smoke.... It's really, really bad.... And it's oil.... 
After a bit of head scratching I had a look around the engine and found some oil leaking from the turbo cassette housing and the smoke was really bad
coming out of the exhaust... So I figured there was something up with the oil feed... Oil pressure is fine, there is no crankcase vapour to speak of
and the breather was breathing pretty well, just as it always had done...
So I pulled the dump pipe from the turbo and found loads of very black oil in the housing and the exhaust itself.... This is bad.... Very bad.... I
thought these ballbearing turbos are oil misers and only need a small amount of oil to keep them happy, but this one is flooding it out... I thought
there might be a restriction with the drain, but that checks out ok as I ran the engine with the drain emptying into a clear container.... So I
thought I had not fitted the restrictor (1mm I think) in the feed line, but that's there too.... Then I noticed that the oil in the cassette was
looking to be a little flooded to me... It is pooling in the top of the turbo where the fitting screws in... This doesn't look right?... Is the
fitting supposed to make a tight seal against the 'peak' of the internal gallery?
Anyone got any ideas?
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humpty
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| posted on November 28th, 2009 at 05:20 PM |
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I spoke to Turbotech on Wednesday about the problems.... After they stopped giggling about the cars power potential, they were a very big help with
the problem... Apparently they have seen this issue before and they suggest I fit another restrictor at the crankcase feed... This time a .5mm
hole.... The current oil feed set-up has a female/female adapter with 1/4NPT to AN-4 threads, at the crankcase end of the oil line.... I step bored
the ID at the NPT end, then machined up a restrictor bung in brass, and then loctite that into the fitting....
Got it back together last night, did a little fettling today. A couple of the local Dubbers came over to help out, we pushed the POS out of the shed.
I made a few changes to the timing map, and turned the key....
She fired up straight away and immediately began to blow a little smoke... Residue from the previous attempt.... After getting the engine up to temp,
fiddling with the carb linkage and keeping an eye on everything, the smoke started to wane... Carb is still not right, but it was looking better all
the time.... Still some exhaust leaks.... Numbers 2 and 3 have some bad leaks.... But it was drivable.
So that's what I did.... I took it for a blat up the street and around the round-about.... Felt good, noisy as hell inside, but no trim and solid
mounts will do that!... Don't have a clue what rpm I was pulling or if it's making boost yet, but it does feel strong.... Will put some fresh fuel
in it next time and do a little data logging to see whats going on.
So all looking good....
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