Project "Marginal gains..."
Turbo Mini Forums

I'm on the Tetenhall road, about 10 mins from the city centre

We'll have to arrange a Wolves / Walsall / Cannock self help group as I still don't really know anyone off the forum and there seems to be more nearby than I thought

Cheers

Edited by Aubrey_Boy on 20th Mar, 2014.

The down pipe has been a compromise between the space available and trying not to make the transition too sharp:



Bolted down to try and reduce distortion but can have a light skim if necessary



The small holes are for lock wire, one each side

The manifold will be finished by this Thursday as I forgot the EGT glands / bosses and if the manifold was welded up there wouldn't be access all the way round

Cheers

Edited by Aubrey_Boy on 13th Jul, 2017.

Nice!

What gauge/size tube did you go for?

https://www.facebook.com/pages/Fusion-Fabri..._homepage_panel

www.fusionfabs.co.uk



1/4mile in 13.2sec @ 111 terminal on 15psi

On 19th Mar, 2014 Aubrey_Boy said:
Hi Carl,

Thank you for your comments, I see your just down the road from me in Wolvo

Are you the Walsall side or more the Tettenhall 'rural' side

On 15th Mar, 2014 evolotion said:


Hope im not intruding in the build, but i built my latest frame around k hubs for the scrub radius improvement. Did this after me and Abs (16vminiclub) put our minis back to back, each in each others cars on the same road. We both had ~200hp at the time, and i was on A(metro) hubs and him on k hubs. difference was staggering.

not to mention, larger wheelbearings better balljoints and much larger CV joints :)

Hi Evolotion,

You say you have built your new subframe around the K hubs, have you used it in this set up? Just interested how it felt as a direct comparison on the same car with your previous A series Metro hubs / steering arms.

Did you use all the whole K Metro subframe & parts or a bit of both?

Cheers

turbo 16v k-series 11.9@118.9 :)

Denis O'Brien.

Edited by Aubrey_Boy on 3rd Dec, 2014.

Awesome build dude, looking forward to seeing this one progress.

I'm just down the road by Willenhall too

Turning circle is shit lol. But no doubt youll play with steering arms and bump steer and whatnot :)

turbo 16v k-series 11.9@118.9 :)

Denis O'Brien.

That is seriously beautiful stainless welding. Exactly what it should look like... No grey blobs here.

Hi Nick,

Thanks, even closer then, Willenhall, I'd be interested to measure some distances on a Clubman front end incase I decide to try and get a properly ducted charge / inter cooler set up (assuming that's what you have?, from your avatar and is still all together?) But still persevering with the roundnose.

Cheers TurboDave,

He does do some awesome work, but even with mates rates it works out expensive, but compared to his normal rate it's cheap! He was doing F1 exhausts as far back as the 80's and still does. When we go through what I want done he listens up to a point and then smiles politely - were are good friends and I know at this point he's not listening anymore and knows what he's doing and I shut up

The two paired 'primaries' are almost done now but deliberately still not connected to the head or the turbo flange:



This better shows the consequences of getting the turbo to hug the block and then trying to get the DP away from it and back down under the sump




Cheers

Edited by Aubrey_Boy on 13th Jul, 2017.

Awesome job, make the manifold I tigged together look like it was done by a blind man with a arc welder

Team www.sheepspeed.com Racing

Worth putting some 3mm k type bosses in there? Since you have an SQ6...

Cheers Jim,

I do a good line in Stevie Wonder welding myself!

Hi Dave,

I knew someone would pick up on that gap at #4 when I was uploading the photo I know what you mean though as stuff distorting has caught me out before.

...I had a panic moment (I wasn't popular) and wanted to double check the EGT mount positions so we had to re-assemble it all (again) to check.

No that areas fine, we had just pushed all the oval sections into the head and the 'Y' sections into the turbo flange (and there had been no real attempt to line things up) to double check the EGT mount positions, so they are all still loose in that photo.

Its welded up fully now and fitted together OK. Don't get me wrong things certainly move around but more like 0.5 - 1.0 mm compared to no gap when we started.

He (He, being the Brackley magician) showed me on a previous project we worked on how he controls how / where things move around, very clever, say he welds the first two pieces of tube together he then reassembles everything, then sees that as a whole everything has moved down a mm or so (I forget which way round it is now) but he will start the next tube joint weld in a specific position so that it pulls the assembly in the opposite direction and hopefully cancels the previous movement. There's no way you can stop it from moving you just have try and use it to your advantage.

No, what I was trying to show in that photo that having the turbo so close to the block (there is still a decent gap between it and the block to stop it cooking the block) that it compromises the angle that the DP comes out at, looks horrible in the photo but not too bad in the flesh.

Hi Alex,

How funny, as I said above, that photo was as a result of having to recheck the EGT positions as he was about to weld the (3mm) bosses in. I was worried that either EGT 1 or EGT 2 was going to interfere with the route for the water pipe. I was going to put them in the oval to straight section close to the head but Ben said not to and I have put them about 50 - 70 mm from the head face. As you can see No. 2 is the problem as you can't get it as close but it will have to do.



The SQ6 has 2 native EGT inputs and the Pi D3 Dash takes another 2 which can be read into the SQ6, I also have some thermocouple to 5V signal convertors so I can feed the EGTs into any analogue channel if the D3 dash interface doesn't work out.



I need to find another short 3mm EGT (like the one shown below) as I have 3 short ones and quite a few 3mm long ones, do you know anyone who might want to swap one



Cheers

Edited by Aubrey_Boy on 13th Jul, 2017.

Just get 3mm K types, then you can position them any distance into the runners as you want and the olives will crush when you crimp them. Moving house this week... I'll have a look to see if I have some, I might... but I seem to remember binning quite a few lol.

If I can help you out i'll shoot you a PM.

You will want to use long ones, and the pig tail 2 loops straight after they come out the boss. Or we find the vibration kills them pretty quickly, can snap off internally too.

nice EGT sensors, I use one fitted to the VAG engines, as they have a nice serial output that my ECU can read.

Team www.sheepspeed.com Racing

Hi Alex,

I spoke to Ben about the whole pre / post turbo EGT debate he said if I installed a post turbo EGT he wouldn't look at it's values anyway as they were meaningless.

As far as EGT's breaking up and failing, he said the same, he hasn't had one cause a pre turbo failure > but as most things we used they were 'lifed' and got replaced relatively early in their lives.

I will only have all 4 in during the time it is mapped / individual cylinder trims for fuel & timing. If they are all similar I will just keep whichever looks 'hottest' and keep a log of this.

I understand what you mean about the longer ones, I may use them, I just know the shorter ones are Inconel and I am not so sure about the longer ones.

Hi Jim,

Are you using Emerald, I remember reading that they used VAG EGT's

Anyway, hopefully we should move on to the 'proper' front top wishbone modifications for the inboard coil overs and forget this engine stuff for a bit

Cheers

wow

Cheers mate

So the manifold is finished:



The EGT bosses are in





Not shown here but the downpipe routing is now being done, between the shear panel and what will become the sump



The main section of the sump will move over to the opposite side to standard and will require a bit of re-jigging as far as a the dipstick goes

Cheers

Edited by Aubrey_Boy on 13th Jul, 2017.

Excellent work, that welding looks phenomenal!

very nice...

I run a supercharger and I don't care the TB is on the wrong side.
VEMS + 12 PSI + Liquid Intercooler = Small Bore FUN!

Looking good mate, since i posted last i have gone and got a job at Primary Designs! Seriously impressive place and a light weight manifold for mine should be on the cards in the future!

Edited by danb41 on 8th Apr, 2014.

My build thread: http://www.turbominis.co.uk/forums/index.php?p=vt&tid=454802

Flickr: http://www.flickr.com/photos/85313398@N02/

Thanks very much for the comments,

Danb41, congratulations that's a 'proper' place to work, primary designs and Good fabrications are the top two of the high end exhaust fabrication places in my opinion.

But being as Primary did my bends at short notice I think that gives them the edge

I look forward to seeing your Inconel 625 creations

Cheers

Edited by Aubrey_Boy on 9th Apr, 2014.