Made in Poland
Turbo Mini Forums

My topic dropped down to the 3 page already so I guess it's time for a bit of an update.

Mainly I've been collecting parts for the build and gathering as much info as possible, so everything is still in pieces. But I already send out the crank to be repaired, it should be back next week. Block is being drilled and taped for 11 stud, head already drilled through (8mm so far to mark the block so it will have to be redrilled).

Since I don't have the car that the engine will go to yet I stripped out the old rusted front end that was laying around. Left only the subframe and engine in and started to trial fit the turbo in between the bulkhead and old 998 that was siting in it.

That's what it looks like after I cut it:


Since the turbo is rather small I think that'll be enough. I'm only thinking about offseting it a bit to right hand side on the manifold. It is a bit tight on the left if I place it more or less in the middle.

The turbo - GT1549, actuator bracket already choped off. It was exactly where I didn't wanted it to be. I'll have to fabricat something from scratch. I'm still not sure where the compressor outlet will turn out so it stays for now.


Other bits already waiting on the shelf:
- set of +40thou Turbo pistons - 9,4 dishes
-Kent 266
-duplex adjustable timing kit
-valve spring
-cam followers
-mains and rod bearings
-set of ARPcap studs and bolts
-head and rod studs should be on it's way from US (they are much cheaper than in uk)
-clutch grey diaphram and ap performance plate

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Crank is finally back from reconditioning. They repaired the damage flywheel mounting surface, reground the whole thing and balanced it. Block is being rebored currently. In few days I should be able to start assembling the whole thing.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Topic droped to 5 page. Think it's time for an update!

Build on the engine is going slowly, but I'm getting there:

Block went to machine shop for boring/honing. I also asked them to drill and tap holes for the 10th and 11th stud. Deck skimed slightly. Pistons are now sitting 1mm below it.



Rod and pistons are balanced. Didn't remove to much material from them. Just enough to get the readings within 1g. Dish enlarged from 9,4 to 12cc. With some head mods I should be able to drop the CR to 8,5:1 no problem.



Bottom end already asseblemed...



... with some help of ARP fastners. BTW they caused huge clearence problem with the gearbox casing.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

SC box ready. Drops will be SC as well.



And here are some pics of how deep I had to grind the casing. It went all the way through so I have to had it welded to strenghten the idler bearing area and cover the holes on the other side. If I remember corectly the ARP stud sticks out around 8mm more then standard bolts do.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

I never had to grind mine that deep....

I'd have shortened the studs personally?

Here you can see the fastners. Studs stick out about 2-3mm from the nut so I decided to leave them like this. I only grinded out as much as needed to clear them. Trial fitted everything every few minutes. Then added the gasket so clearence should be just right after itightening it down. To be honest I searched the forum for simular problem. Only found one person mentioning it.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

What is the casting number on the front of the gearbox?

DAM5626 is the normal A+ casting.

ahhh, you mean the Mains bolts... Well, reason few folks have problems, is few folks use them.

Re the issue with mains studs.....RTFM..... Its in the yellow book, its not a new problem, been around for years.

no need to RTFM now, I did exactly what it would suggest anyway I do admit I missed it in Vizards book and I did searched "main bolts issue" instead of "main studs issue" on the forum.

Anyeay it's grinded, it's welded, it all fits nicely now. Head is next.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

And this is how it looks so far. Point me in the right direction if you see anything odd.

Material removed in the valve guide area, rest of the ports is simply cleaned from all of the bumps and rough surfaces. Inner and outer radius smoothen out. I'm planing on leaving rough finish on the inlet and polishing a bit on the exhaust port.

Only polished out one chamber so far. I'll be enlarging them a bit to get 24-25cc volume. Then it's off to machine shop to fit new guides, cut the 3-angle seats and to get it skimmed a bit.

Edited by SadamPl on 14th Oct, 2015.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

I don't think my build thread gets much attention but since few people are complaining about not much going on on the forum I'll update it anyway. Btw I agree that forums are becoming less and less attractive. Our polish Mini forum basicly became a BINI site now. It always lacked such a helpful and knowledgeable user like TM has but now we're getting 2 or 3 classic mini related topics per day and that's it. It's hard to call it discussion.

Anyway back to the topic. Prior to putting block on the gearbox I adjusted timing. If I remember correctly on of the inlet valves opens slightly sooner then other three (1,5 degree difference, cam is Kent 266). I'll be checking that once more tomorrow and adjusting accordingly.



Working on the head took me few days and then it went to machine shop for light skimming, fitting new valve seat, guides etc. Put some new paint on it and got it assembled ant this how it looks now:



Started working on the exhaust manifold as well (Big thanks to Ben H for sharing CAD files for the manifold flanges once again). No big progress here yet as I'm waiting for the turbo flange to be cut. Only managed to make the center branch fit with inlet manifold and sorted out a general idea how I want it to fit and look like.




Still a lot to do but I'm sppeding things up now. Since it's almost Christmas I thought it's a good time to order some new shinny bit as well so I've got a new alloy radiator ready to go in, ignition system on the way, all new clutch hydrualics already in place and loads of other small bits waiting to be fitted. There's nothing better then unboxing new parts shortly before Xmas

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

All good progress.

Interesting that you still don't have a car for it all to go in!

Fastest 998 mini in the world? 13.05 1/4 mile 106mph

www.twin-turbo.co.uk

well done sadam , i think it will make much more power than you expect !!

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

Looks good :)

Thanks guy. Little appreciation always makes work easier and more fun.

No worries on the car, it's due to arrive any day now. As soon as I have it I'll share some pictures.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

I spend a few hours checking the cam timing today (measuring on the valve caps) Full lift is right where I want it.
103-108 degrees on 1 cyl
104-109 degres on 2 other cyl
and 105-110
Average - 106,5 degrees. Yes I only measured it while rotating crank one way (I know the proper routine but it was only to check earlier adjustments with head in place). No need to lecture here

If the duplex vernier chain stretches around 1,5-2 degrees I'll end up with 108 or so. A bit more then Kent figures but from what I understand it may help with turbo spool up.

What got me concerned is valve opening angles. The vary up to 12 degrees on inlet and 9 degrees on exhaust. Valve clearence set to 0,4mm. I know Graham Russell way of dealing with it:

http://www.minimania.com/Project_Small_Bor...__Cylinder_Head

But I noticed nobody here actually mentioned it. No real benefit in road going turbo engine?

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Another few hours spend on timing today. I was trying to figure out the best way to achieve required figures yet beign able to replicate that with the engine in the car and no degree wheel fitted and I think I've got it. Trick I used is marking flywheel when the crank is at angles where inlet or exhaust should start to open.

I used 1 dot at exhaust opening angles
2 dots on the inlet opening angles
and 3 dots to mark 106 degrees ATDC on no 1. to be able to check whether timing is off in the future.

Having the non verto clutch setup and cover with inspection hole helps a lot but I think I'll be drill them out on other engines to be able to use same method. Anyway seting up DTI on valve cap and seting 0 clearance at reuired angle is an easy job once everything is marked.




Clearnces vary from around 0,35mm to 0,45mm. I'm afraid it may end up with a lot of noise which personally hate. I'll recheck everything after first startup and breaking in the cam. BTW flywheel timing mark was spot on, crank pulley is about 1 degree off.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

75' Mini special deluxe.
1275 A+ engine with turbo on the way...

Looks like a good build! What's been the plans with the car regarding looks? (Sorry if I missed that but of the thread)

As for the cam timing I don't know how accurate the machining is but 1 degree is more variance than I would have expected. I take it it's a new cam?

http://www.turbominis.co.uk/forums/index.p...tid=469104&fr=0

Thanks!

You all need to wait few more days for the car to be revealed

I don't think timing mark on crankshaft pulley makes a lot of difference on a stock engine. Besides in this case it would cause igniotion timing to be actually retarded. Now I know it I'll take it in to consideration.

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Still a few more things to put on the engine but I'm waiting for some stuff to be machined. I'm also seriously considering fitting electric fan only after checking out some other build threads. But for now I need to move my focus to other bits. Carb came back from glass blasting so it was about time to start to put it together. Still waiting for some parts to be zinc plated. Pop up valve removed and hole in the disc filled with tin. Other then that I felt like i need to follow the "making things lighter" trend and I thought carb dashpot is the best place to remove some material off :-p

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Still a few more things to put on the engine but I'm waiting for some stuff to be machined. I'm also seriously considering fitting electric fan only after checking out some other build threads. But for now I need to move my focus to other bits. Carb came back from glass blasting so it was about time to start to put it together. Still waiting for some parts to be zinc plated. Pop up valve removed and hole in the disc filled with tin. Other then that I felt like i need to follow the "making things lighter" trend and I thought carb dashpot is the best place to remove some material off :-p

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Due to weather conditions it took much longer than expected but car is finally at my place:

Made in Poland build thread:
http://www.turbominis.co.uk/forums/index.p...tid=570363&fr=0

Very nice. Fresh car, new engine - How much more is left to do, or you just have to build it up?

Edited by PhilR on 3rd Feb, 2016.