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Ian's Saph Cosworth with BOA

Started by IansSaph, January 30, 2008, 16:29:47

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IansSaph

Started sunday morning with a pile of bits, including a set of headers of a subaru i've cut up. an old 24v manifold, lump of steel and a T2.


Welded the manifold to the steel and made a Jig for the down pipe.



I'm making the turbo manifold a direct replacement for the standard manifold.

Cut off the cast manifold to leave you the flanges in the set positions.



I've taken loads of measurements and the whole thing should fit in. i'm working a little blind as my workshop is at home and the car is on my Mother-in-laws drive a mile away...

Although my primarys arn't same length length, the design imitates that of the 2wd YB manifold sothe primaries combine then i have a bend into the turbo, i reckon this encourages the gases into a swirl in to the turbo meaning i might flow better, Either way its only a tiny T2 i'm not looking for big gains so it will be fine.




i've just got the collecter to be burr inside with the die grinder and the last primary to weld inplace then it will be read for the first of many trial fits. Unfortunatly i've used up all my playtime now for a week or two...

Janspeedcapri

I well confused but YOU know what your doing - thats the main thing     becareful not to warp the flanges when you weld them up - they won't seal and could crack the welds when you bolt it up. all in all good stuff

IansSaph

going to get it skimmed, the cast flanges are only temp as i don't expect them to last. just a temp quick solution. Will make loads of sence when i get it bolted in place. more soon....

going to get it skimmed, the cast flanges are only temp as i don't expect them to last. just a temp quick solution. Will make loads of sence when i get it bolted in place. more soon....

Janspeedcapri

Quote from: IansSaph
going to get it skimmed, the cast flanges are only temp as i don't expect them to last. just a temp quick solution. Will make loads of sence when i get it bolted in place. more soon....

going to get it skimmed, the cast flanges are only temp as i don't expect them to last. just a temp quick solution. Will make loads of sence when i get it bolted in place. more soon....
yeah  


yeah  

IansSaph

haha.... i know. it will get thrown on and be there till it breaks...      

IansSaph

Bit of an update,

got some jobs done on sunday, got my new starter motor fitted, the replacement came with the long power lead attached, as mint is in good order i used the other one as an earth lead from the starter to the battery. should rule out any earthing problems in the future.... i hope.

Fix my gear selector, turned out to be nice and easy.

did some cutting, soldering and taping on my loom,  bit of the wiring was tight, all nice and neat now.

i started to fit my remote filter and oil cooler, but my connector for the sandwich plate is the wrong size. right annoyed. job for another day.

routing my oil pipes with a stinking hot turbo manifold to consider is annoying. typically none of the braided hoses i already have will suit, so its a good length of the rubber stuff and some heat wrap.

i've been trying to find a bargain cluch master cylinder, an impreza WRX one is looking faviourte, going to borrow one it will be close to the O/S head but everything is close in a saph engine bay, i bet its easy with a poxy 4pot YB, loads of room.
Going to use a BMW M3 slave cylinder, (its the same as the 316i but M3 sounds better) looks like it will mount on the Type 9 mint with loads of room. Also looked at using a electric line lock as a kind of launch control, conected to the cluch to release at 3k or what ever suites... (don't think my type 9 will like that much tho....:-)

MOT next week.... wish me luck

Janspeedcapri

yeah, hope it goes through mate. won't holding it on the handbrake do for launching?

IansSaph

Quote from: Janspeedcapri
yeah, hope it goes through mate. won't holding it on the handbrake do for launching?

it should do like, and wheres the engineering fun in holding it on the hand brake!?!?!

   


IansSaph

Konis and the missing polybushes bought,

i'm hoping for quite a nice driving car once i'm finished.

IansSaph

Its ALIVE!

thanks to an enthusiasic mate, we pulled the old girl out of the garden last night, got her running and made a list of stuff for the MOT on saturday!

She will be back on the road just as a plain old 24v with vectra injectors, the twin turbo idea has been shelved for a time when i'm not so skint.

Looking forward to actually driving her again.... its been 9 months since i abandoned her in the garden, and two months since i last looked at her.

Janspeedcapri

Glad to hear that   Good idea on the turbos - you want to do a conversion like that properly and its not like the things slow as it is for now  

IansSaph

the old girl proper does not want to give in, over the passed two nights it has burst fuel pipes and air locked and and and

Finally the last straw was at mid night just as i was happy with her running i went to put her off the drive and the clutch is stuck to the flywheel. its too late now for the various 'unsticking' methods. its not the quietest car!

Maybe tomorrow, my sales punto will have to have my MOT slot in the morning

IansSaph

went for some petrol last weekend.....



MOT booked for saturday. new years res to have her on the road.

IansSaph

we have an MOT!

took a video of a bit of a thrash home from the teststation, i'll try and upload it later




TwinTurbo


madasahatter

Congrats chap i did like the red snowflake pic too this morning        


Taps

Quote from: IansSaphhttp://www.facebook.com/video/video.php?v=43811477668&ref=nf]http://www.facebook.com/video/video.php?v=...7668&ref=nf

not sure if that link will work..... give it a try

A. Will only work for people who have Facebook

B. Its not working  

Cant ya load it on the Pbucket

Dave

#49
You're defiantly getting there.

Keep the faith, little problems is all part of the fun.

Congrats on M.O.T
Dave

IansSaph

Quote from: TapsA. Will only work for people who have Facebook

B. Its not working  

Cant ya load it on the Pbucket

it does work but you have to be allowed access.... so i'll chuck it up to photobucket, there isn't enough sideways action for madz so be warned its tame! LOL..... big file... taking some time.


robrs2

I like the way you jigged up the manifold, top job.

IansSaph

Quote from: robrs2I like the way you jigged up the manifold, top job.

yer i was quite impressed with myself like...... hope it fits.....

robrs2

If your ever looking for 2 matched turbos go for Skyline R32 or R33 GTR turbos. There small and spool up quick, good for 430bhp

Dave

#55
Most of that video looks like your driving in the dark with no lights on
Dave

madasahatter

Nice to see the car running again i did enjoy the video, car does sound nice as well          

IansSaph

Quote from: DaveMost of that video looks like your driving in the dark with no lights on

it does mate doesn't it, i was quite upset with the quality, typical nokia, all the photos look dark when you take them off too.

shame,

might mess with the settings and see if i can improve it.

IansSaph

Quote from: robrs2If your ever looking for 2 matched turbos go for Skyline R32 or R33 GTR turbos. There small and spool up quick, good for 430bhp

thats interesting, i want small ones, i have two T2s but i can see me getting bored with 300BHP quickly.... its very important fo everything to fit the engine bay properly too,


IansSaph

In typical sierra style, i put half a tank of fuel in last night, though i'd have a blast up the bypass from the lights..... clutch cable snapped.

Hydraulic upgrade time. LOL

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