Login Form



 
Turbo
New engine interior
Wednesday, 05 August 2009 01:00

Image

This is the biggest nightmare of every VMax engine. The O ring blows out sometime.
Yes it does ! No, I did not pull too much throttle when cold since I watch my oil temperature.
This will overcome everyone sooner or later....  And also, this is not due a turbo setup. Because the turbo does not pressure the oilsystem at al !

 

Image 

I had a lot of luck ! Piston is missing a lot between the rings.
I drove 1000 km with this piston !
Problem I had that I could not boost the engine.
When it happened, then I blew by the cranckcase too much and all the oil came out the vent tube.

 

Image 

I did a modification on the oil gallery.
After a search I found that a few more people did it this way. The ring relies higher and thus deeper in the seat.

 

Image 

If you change it all in this way. Your Orange O ring will never pop out anymore.
This is the only best way to solve the problem. All the solutions with extra pressure on the bottom, braces and other rings DO NOT WORK !

 

Image 

I had the engine open and found out that my rods are worn out due high revving with my Flatslides and later on the Fuelinjection.

 

Image 

Also had to choose new pistons. They were special made for my turbosetup at JE pistons.

Image 

Also bought a cometic steel gasket kit and a DYNA 3000 ignition unit special for the boosted application like the turbo I have.

 

Image 

Carrillo and JE piston mounted together... What a shame that this will go into an engine and never see it back...

 

 Image 

Rebuilding my engine...

 

 Image 

Last view of the nice turbo pistons...

 

 

 

Thanks to http://www.dynoman.net/ for the advice and service !

Everything runs fine now and did a 10.000 km with 1 bar (14 psi) boost !

 

 
K04 Turbo
Monday, 19 March 2007 10:52

Image

At Ebay won an Audi TT K04 turbo from Borg Warner ( KKK group ) 

 

Image 

Also won at Ebay a GSXR600 throttlebody kit from a 2001 model.

 

Image 

From http://www.800bhp.com/ bought an adjustable blow-off valve.

 

Image 

XS racing has a nice wastegate. This one equiped with a 3.6 psi spring.

 

Image 

Fuel pressure regulator with a small meter and is adjustable within the needs of the pressue and also has a turbo pressure reference input.

 

Image 

Tubekit for the airtube with silicon hoses.

 

Image 

Testing the bodies and measuring to try it fitting on the heads.

 

Image 

Topview of the testing.

 

 Image 

Special thing has to be done like making the axle 68 mm longer than stock. Welded on with a TIG torch and placed the notch at the end.

 

 Image 

Had to make a plenum for the intakeside. Calculated the size by the manual of Corky Bell.

 

Image

Here a friend welding the plenum together.

 

Image 

Welded the box together. Now have to polish it.

 

Image 

Topview of the plenum on the bike.

 

Image 

Airtube fitting and searching for the right angles and way to route it.

 

Image 

Sideview of the air tube.

 

Image 

Right view of the body connection wheels.

 

 Image

Shortened the output of the compressor housing by 4 inches and welded a new exactly 2 inch output on it and polished the housing.

 

 Image

Bling factor !
Will fine polish when ready with Belgom.

 

 Image

Fuel distributorblock and gauge mounted on the pressure regulator.
Separate fuel lines for each injector.

 

 Image

Vacuum/pressure lines for the fuelpressure regulator and blow off valve on the manifold.

 

Image

Bought at www.uitlaten.com a set of bent tubes to make the exhaust made of stainless steel.

 

Image

Started sawing and trying to fit the piping.

 

Image

After a lot of time Frans and I got this pipe to the turbo ready.

 

Image

Other side of the piping.

 

Image

The downpipe and wastegate connection started to get some shape.

 

Image

Underside of the engine fits tight.

 

Image

Rear part of the pipe fits smoothly to the underside of the frame.

 

Image

Exhaust exiting the frame to the rear of the bike.

 

Image

Full view of the exhaust pipe ready welded.

 

Image

Copper gasket sawed with a jigsaw to tighten the pipe to the turbo.

 

Image

Desgined my mufflers and I like the shapes it is now !

 

Image

Connection side to the pipe.

 

Image

Rear view of the bike with the mufflers mounted. Color will be changed when the bike is finished.

 

Image

My bike at the Dutch www.motor-forum.nl megameeting in Veenendaal

 

Image

Pzyko from www.motor-forum.nl photographed me while entering the meeting area.

 

Have to finetune the bike and will fit a boost controller solenoid to regulate the pressure.
Now boosting with 5 psi pressure and it runs great and the frontwheel starts lifting till 4th gear !
Designing heat shields and water catchers to prevent burning my pants and cracking the turbo from water.
Will post some results soon after a dyno day...

 


© 2012 Saarloos.net