mk2 granada turbo build

[limey]

i did join here in 2011 but got lost in work and home stuff.
however ,now the turbos on and runs,sumps swapped and new exhaust sorted. dash changed a tad and extra gauges etc fitted to suit (or not if you dont like gauges) and a few other bits tinkered with along the way. not much info to be found on the web that helped me but a couple of guys on the granada club i use have had the answers / info i needed when i needed it so its not all bad.
ive eventually run out of petrol but after a top up im confident ill have it running enough to get it out the garage its been sat in for the last 20 months
its a suck through single turbo set up and uses a rotamaster turbo.turbo was rebuilt by turbo technics and the missing components have been fabricated or suitable bits obtained from a very helpful parts distributor who let me look through their stuff until i found the
bits i needed.the carb is an su and if im honest,i know theyre simple but i have never used or worked with one so its all newto me.
from the sump swapping while the engine was still in the car to the exhaust its all been on on simple car ramps which although free,made things a bit more awkward.....like kicking the inspection lamp accross the garage floor while the tanked emptied over me during the pump fitting.found a few sharp edges along the way too....but its done and now its all history.
next i need to get it to a tuners for setting up,ill have a looky underside too for any mot issues that may be under there waiting for me.
is anyone here running a suck through turbo set up on a cologne engine????
heres a few pics from along the way

[Grey]

Nice work there mate!
Love the look of your granny. 

[limey]

Thanks mate,I've had the car for 20 years now and done most stuff to it,but this has been the most testing.

[Dave]

I like it too 


Also like that you have gone for an old school type turbo install which would be true to the car if done when it was new.

[limey]

thanks dave,
the turbo wanst ever planned though,i was having a meal with wifey when a mate texted me an ebay number with the message "ends in
1 hour". meal interupted and a £70 bid dropped in and i won the parts shown above (all rusty and parts missing)  for £32!
£350 saw  the turbo rebuilt and the rest is made up from various parts that i could get to fit. the hardest part was the sealing ring joint for the crossover pipe where it met the manifold on the turbo side.i emailed janspeed and they never even replied????
every exhaust place i went to just couldnt help at all??? they all wanted part numbers despite me having the crossover pipe with me.southern motor factors (where i tend to get all my parts)let me rummage through their exhaust parts and armed with the joining pipework i found a suitable part in minutes. just walked back in the office and £1 later i was sorted. many of the turbo bolts were older thread patterns but i found a "universal fasteners" in gravesned who stock pretty much every desired nut and bolt combo you could need.
other than learning the hard way not to but cheap used parts off ebay its not been mega hard to get this far at all. i nabbed the silencer (not that it does much silencing) for 99p off ebay and had spare stainless tubing in the lock up so that only really cost the price of one flexi joint a few clamps and a rubber. the sump swap was by far the most frustrating job. due to time limits ,mainly the kids after school stuff and my long hours at work i couldnt have anyone round to help as i just did parts as and when i had time. the car was facing into the garage so an engine hoist would have been impossible so to swap the sumps i simply set the timing as a mate suguested,took the dizzy cap off,removed the engine mount bolts and started jacking the engine up.
the car was on ramps already so it was a just a case lots of wooden blocks on the trolley jack and jacking until the heads met the bulkhead.
didnt leave a lot of room and with only 14" of under car clearance it took  a nightmare 4 1/2 hours to get the old sump off and the new one (baffled and oil return piped) on. i used the 2.9 all rubber gasket too this time after many nightmares with the silly cork and rubber ones. a smear of silicon all round to keep it roughly where it needed to be and it was nearly there. it got a bit tight under there to the point where i needed to take the bellhousing bolts out the bottom just for that extra  couple of mm clearance. cost me a whole days leave from work
exhaust studs were shot too and everything seems to foul on something ,even the original  mechanical fuel pump was in the way of the turbo manifold
im guessing the original car it was on had an electric pump as thats what i ended up doing. luckily i work 3 roads from "tickover" who can supply most cologne parts and cheap too so a blanking plate was hade for a couple of quid.
all in all, it is possible to do the swap on your own without removing the engine from the bay ....but for the love of god i'd never tell anyone else to do it. i was bruised for days afterwards
i was hoping though to have the only set up like this around, ive not seen another mk2 granada  with this turbo on and i do like having things that no one else has. the car was a 2.3 gl to start with so a basic turbo set up works nice for me and the  cars lower spec origins,theres a few turbo technics ones out there but ive not seen any janspeed ones.
im not expecting a lot from the turbo if im totally honest,but if i can get @150 bhp from it, id be absolutley chuffed to bits
would gladly take any info at all on the set up though,absolutley anything that may be of use is welcome

[mk2 cossie]

Welcome along at last Limey 

Be good to get your wagon back on the road for some show convoys again, and of course going through the noise test tunnel to see who's loudest still 

[limey]

hi mate,
if im honest,even with just the front pipe and no other exhaust on my car.....yours is still louder
that said though, mine will be quietend down before regular use,im getting shy in my old age. gonna look for a rear box as soon as i can afford it

[Lemon-Ade]

Hi mate , very nice I like the old school approach. Do you know who is going to set it up yet ?

[limey]

old school thing seems to be popular here ,but in all honesty its mainly like this beacase of a couple of things.
firstly ive had the car for so long now its been cool, common ,banger racing fodder, unwanted by all  and now kinda cool and retro again ....gone full circle.

i didnt start doing much to the car until a few years ago however  id spent many years ammassing parts for the "i'll rebuild it one day" moment.
a mate gave me a few good panels and with good basic tools and also a few good knowledgable mates at the end of the phone and emails.i had a 2 1/2 year crash course in granada mechanics.
as for tuning im struggling with suitable places,so far ive been flatly told "sorry mate, cant help you " or "bring it down, we'll have a go". neither will see the car.
i need an experienced place with rolling road and a big box of su needs and jets.
im not expecting big power but the fact ive never seen this set up outside a rover v8  or 280z engine  bay makes me want it even more. an old car with old fashioned turbo just looks right to me. i would love to be able to build a supercharged cologne but just doubt itll ever happen. that said,if i had a spare v6 in the engine stand at work id probably try ......im like that .
ive heard many people knock the cologne  and also the type 9 box ,but mine had knocked up 174000 miles and the last 74k were all mine. personally i like the fact that you can declutter them nicley too,mine looks pretty bare which is something id wanted from the start.
back to basics and just the bare minimum works for me all day long

[Lemon-Ade]

I loved my one



The type 9 was fine behind that so yours should be ok . Prob not to many places that will still be doing that sort of tuning now days. I like the fact you got in there mate and got it done.

[limey]

thanks

[limey]

tried her for a long run to check for leaks....................and leaks there were
i had oil escaping out of everywhere,i felt red adare trying to cap them.
a new rocker gasket,some pfte tape and some tightening up of bolts that had rattled loose later and she was ok. well theres a nut that holds the fuel pump blanking plate on that has a tiny drip every now and then but ill address that later.
once warmed up she runs like this (vid link below),sounds tinny but thats the lousy video sound on the cameraphone. its actually a bit louder than i had wanted so ill be looking at getting a suitable rear box on asap. my days of loud motoring are long gone now and have always preferred to hear induction roar more too.
ill be taking the old girl ,fingers crossed to sanspeed in bexleyheath for setting up. im just hoping all goes well as things very rarely do for me
http://youtu.be/Qv_tYLcOvUU

[Grey]

tried her for a long run to check for leaks....................and leaks there were
i had oil escaping out of everywhere,i felt red adare trying to cap them.
a new rocker gasket,some pfte tape and some tightening up of bolts that had rattled loose later and she was ok. well theres a nut that holds the fuel pump blanking plate on that has a tiny drip every now and then but ill address that later.
once warmed up she runs like this (vid link below),sounds tinny but thats the lousy video sound on the cameraphone. its actually a bit louder than i had wanted so ill be looking at getting a suitable rear box on asap. my days of loud motoring are long gone now and have always preferred to hear induction roar more too.
ill be taking the old girl ,fingers crossed to sanspeed in bexleyheath for setting up. im just hoping all goes well as things very rarely do for me
http://youtu.be/Qv_tYLcOvUU

Good work mate! Hope that it will be over expected. 

[whiteestate]

Love the old school carb on the turbo inlet. Turbo cars on carbs sound amazing they make all sorts of spaceship like noises popping and banging good effort pal really liking the colour too 

[limey]

Thanks mate,I've never heard one so I have absolutley no idea what to
expect although from what you've just said I'm quite looking forward to it now   

[mk22door]

This is awesome 

I remember this being in classic ford mag a few years back is that right?

I love the look of the old Granada, yours sits really well!

Afraid i can't give you any advice - all the best with the tuning & setting up I bet it will sound awesome mate 

Hats off to you for going at it blood, sweat tears and all that, you must be chuffed as..

[limey]

Thanks mate and your right,was May or June 2011.



it also made a small appearance in retro cars mag and also in retro ford too with their show/track day  reports.
The car was on the classic ford mag show stand too in 2011 but had developed a real lousy miss by then(still drove it there!)
I built the car to promote the MK2 granadas and show that theres potential in them. Wasnt exactly many modified mk2's out there so
modified as much as possible. every part was altered or changed for a sligtly different one. even the grill badge is off a fiesta just so its thicker than the standard one
anyway , the missfire turned out to be carb related and money was real thin on.the ground so I opted for the sorn and left it in the garage.
Then ages later I thought I'd try dropping the turbo in seeing as I had most the bits to hand and a new carb would have been over two hundred quid to replace the old one
Turned out I didn't have all the bits at all .....but I've got this far by trying stuff. I've been given advice by Stevie turbo and also mk2 cossie from here but mainly its been  trial and error and helpfull motor factors. one even let me rummage through their stock so i could find an exhaust seal/joint ring to suit which made things so much easier.
I had hoped to get to classic ford mag show in June but think local runs are gonna be safer till I've got all the teething issues sorted.
The biggest problem I've had is no one else seems to have run this set up, mainly as its not very tunable once running  so info
has been real scarce. If anyone knows of anywhere I can see vids of a similar set up or get any info  I'd be greatfull to see it.

[limey]

leaks were all sorted but then it developed a wierd ticking noise,like a cable tie resting against the alternator.....but it wasnt
all signs pointed to the release bearing so a new clutch was ordered and with the help from a good friend the friday night mission began.
8pm start and by 12.30 we had the box out,new rear seal and clutch kit fitted and all back in the car .instead of the jack we used arms and legs to get the box back on the engine and she slipped on first push which was superb
by 02.30 everything was back on , prop,zorst ,.,......the lot.
however, when refitting the starter it appeared that the oil return feed spout on the sump was facing slightly out of alignement.
no chance of getting the sump off  so we fired her up to see if the noise was gone.
there was a ticking but a different sounding one???? seemed to be quietening down as things warmed up too so maybe the gears in the box were shy of oil through being at a lousy angle for so long.  the release bearing was def shot and rusted out though.
the new sump with relocated spout is being nailed together by another mate and the new gasket is ordered too.
i swore id never do it again but ill fit the new sump with the engine still in the car.,.......its a total cow of a job but its gotta be done.
the hanging bar is already accross the inner wings and ill try to start raising thing up as soon as i get the front pipe off the rest of the exhaust.

[whiteestate]

Its a real pain when things don't work out glad its all in hand though 

[limey]

I don't mind ,the cars running out of things to throw at me........most stuffs been changed now..

[limey]

a lots changed since the last post and not alll for the good.
been driving the car trying to stop the oil weeps and although it runs enough to get around its gutless from a standstill an donly actually does something at full chat.
that said the leaks havce been reduced by fitting big breathers on the rocker covers.
two weeks ago i took it to a rolling road for a test.
turns out the guys who said it wasnt boosting at all werent entirely correct. it is but very little.
a suspected jammed wastegate was investigated by mk2cossie (paul) and myself on wednesday
the shaft from the diaphram to the wastegate is siezed solid. its mostly apart now and im working on trying to un sieze things.
it would seem that the wastegate is fitted in front of the the exhaust port for cylinder 4/5. so im thinking that if those two ports are being forced straight through a 1" wastegate pipe into the front down pipe could that be causing the exhaust gasses to build up and be forced into the crank case???? that would explain my ongoing oil weeps.
so this weekend i'll try to get the wastegate rod moving,if it wont ill have to take it all off the car and see if i can do a gynacollogist jobbie through the inlet to the manifold via and exhaust port pipe.
despite almost no boost at all and the eninge with its partially blocked port and breathing through a single sd1 su carb managed a 119bhp and 138 lbs of torque. i know its not much but its not a bad starting point to go from.
any advice or info that may help at all  is greatly welcomed
heres a vid link of the dyno


http://youtu.be/ZcH2DdDJZCs






Wastgate pipe damage.......will see about repairing that  later



The actuator rod is seized solid.

[mk22door]

Hope you haven't got too fed up, is their any good progress?

[limey]

have got very fed up but was still messign around until 2am sat am. new wastegate attached and just needs vac pipes and a screamer pipe to finish. unsure of the wastegates  psi on teh spring so will google colours and psi for turbo smart products. i do have a comperessor and tyre pressure gauge so will be able to knock something up. i did post but in a dif thread,will copy to here,see below.

righty then,wastegate arrived and it was time to work out how to fit it to the manifold.........
i sliced the old system away to reveal a siezed solid wastegate valve so i was right in thinking that it would never free of in a milion years.
after a look over things i started working out a workable plan of attack. the hole inside the manifold was a tad smaller than the tube fitted to it so i sourced a suitable tube to insert. by doing this i completely blocked off the old wastegate bypass pipe . the flanges that arrived with the kit looked like pollished ally and werent magnetic,a text from paul 9mk2 cossie)explained that i was a muppett and theyd be made out of stainless.
so grinder in hand i set to work. im not a welder by a long shot but its all together now and its almost time to try and source a screamer pipe. i had planned on running the excess boost through the front pipe but will be looking at venting it out descretely from the side of the car.
still loads to do and there are still "bits" required but nothing crazy. its all back together ,just a few nuts to tighten up and line up but once ive established the springs psi and if it suits i should be all over it. ive got a variable boost controller too but will ignore that until its at the dyno for setting up properly. once everythings sorted i'll leave it all alone and just drive.dont suppose anyones got an angled  38mm screamer pipe for sale real cheap?........................................................

[mk22door]

Working until 2am, that's the spirit!

Love this Granada 

[limey]

cheers mate
i worked nights for 17 years and its hard to get it out the system.my day starts at 4am and the only time i get to mess around in the garage is on a friday night.not too bad in the summer but it can get cold in the winter. woken up sat on the garage floor with a spanner or socket stil in my hands before but its all in a nights work.i found some infor regarding the wastegate yesterday and have emailed it to a mate who likes reading that kinda stuff.helps too as he'll read it properly and see me making any mistakes before i make them . should have this all back together by the end of feb if all goes well. was due in court a tteh end of jan over an incident in 2012 but the other drivers solicitors put a 50/50 offer on the table and depspite me not being in the wrong,my barrister said it was prob best to take it i'll cancel teh day off and use it for a dyno day instead when im all ready.i'll try to get the exhaust all back on this friday night and that will just leave the wastegate boost connector to the hardpipe and the plumbing to sort and we should be ready for round two.

[mk22door]

I'm trying to do stuff on the driveway at the moment - it's like a wind tunnel and a little dangerous i feel for axle stands etc. Wish I could get in the garage but our lass' mini is in their rotting away! I'll have to strip that out this year and see how bad it really is 

I do shift work and feel knackered a lot of the time, so don't get much done lol!

Good work fella 

[limey]

hahaha,been there too. i stripped my car to nothing on the hardstanding behind my old house. fitted the complete exhaust while the car hypnoticly swayed back on forth on the four axles stands at full chat.
heres the £31 turbo kit.....or bits of a kit that was bought half way through building the car a few years back



heres the su after mk2cossie got his "pollishing hands" on it

the pipes were shot but a welder friend arc welded them all good for me for free .
this is where tha car sat motionless for 2 1/2 years while i replaced everything and welded up all the holes it had developed. two arches welded on and up,new wing mount rails  and that was before i started rebuilding the a posts.......
heres the original engine bay

the "freeflowing foot cooling air inlets" that had developed too


all the work done for this foolish turbo conversion has been done on standard halfords style ramps. gear box ,clutch out and alos teh fitting of three sumps and three gasket ,full exhaust made up and fuel system changing done with a 14" floor to sills gap. made getting out interesting when i dropped a load of fuel out the tank while holding the inspection lamp
owned the car for 21 years now and id guess that its been off the road for various refits for at least 10 of those.thios will be the last one though

[mk22door]

It must be love!

Why will this be the last time?

[limey]

mainly because this time i bit off more than i can chew. tried something that i knew nothing about and had real trouble finding any info about. its been a game of trial end error and at one point the car sent me to a plastic surgeon.
once its all sorted ill finish undersealing the whole car and fix the central locking. the rear ns quarter needs a repaint thanks to me dropping a pair of repair sills on it too.
it'll stay as is once running right and it will just be normal servicing and tidying up. that said, a mate keeps putting ideas into my head,the latest being fitting the capri inj system onto it. the car owes me £8k+ from the last 10 years has eaten away so much time.i will be looking at dropping in a pair of green 3 point harnesses up front and poss a rear cage but purley for looks,i wont be doing anything silly in it.
that still leaves sorting out the radio and amp etc but first i need to do the following

source a decent type 9
source a decent diff
fit towbar (already got one )
fix water temp gauge
rewire fuel pump as it suffers starvation of volts when starting sometimes
sort central locking
fit new drop links on the o/s,not urgent but once done i'll be happier as i did the ns in the spring
hopefully refit noisy back box
wire reversing light via relay
fit two screws in steering column plastic surround
fit the two new headlight connector boxes onto loom (current ones are manky but work,better to fix before they fail tho)
tint headlight glass yellow

[mk22door]

So not the last time as in selling it!

That's good then