28-12-2014, 01:07 PM
Was pretty chuffed to be presented with this at the Christmas meet at the beginning of this month:
[attachment=20790]
So now i've got to finish it, else they might take the trophy back.
I realised i've been blithely listing items dealt with and not really given any detail on anything, so for anyone interested here is a more complete breakdown of the fabrication work done so far.
The TD05 cold side needed a couple of mounting lugs chopped off for clearance and some sort of tube on the outlet that i can stick a silicone on. Once i'd taken the dremel to it i passed it on to Jim at RH Davey (Daveyboy on the '6 forum) who did this for me:
[attachment=20780]
Jim also welded up the egr outlet on the inlet mani elbow, which we then drilled and tapped for a boost take-off. We didn't have a suitable fitting, so instead we welded two fittings together and wound her in with mole grips.
[attachment=20786]
The GT17 also had a few extra bits of metal that were in the way, so out came the dremel again. As with the td05, i needed a way of getting a silicone to sit nicely and preferably a bead to hang on to, the next pic shows what we came up with. This was one of a few jobs taken on by Emma (other half of samass), hence it being neater than most other bits of the build.
[attachment=20784]
Next up was gauge feeds for the exhaust side - emp and egt. As ever i was too cheap to buy proper fittings, so spent some time with a drill, tap, welder and brake pipe flaring tool. I had trouble finding a suitable flat surface for the screw-in fittings to seal against, so had to come up with alternatives. The egt probe came with fittings, so i opted to use those and when it came to tapping the thread in the manifold deliberately didn't run the tap all the way through. This means the thread is effectively taper-fit and seals nicely when would up tight. The next challenge was where to put it, as you can i was juggling between clearance to the intake mani runners and being able to get a tool to the cut-down exhaust stud nut.
[attachment=20788]
The emp gauge feed is particularly bodgetastic. I felt it would be a good idea to have some sort of cooling between the exhaust manifold take-off and the gauge in the cabin, i had a few old brake line fittings lying around which looked about right for the job. I cut the female end off an old flexi, drilled a hole in the mani piping and welded the bastardised fitting over the top. This meant we could simply make a copper coil from some brake pipe, bang a male fitting on and flare it.
[attachment=20791]
[attachment=20792]
Now i needed a way to get all these gauge feeds from the engine bay through to the cabin. For some reason I seem to have taken the photo before this was introduced to the holesaw, but you get the general idea, the top-left hole is the one we modified.
[attachment=20781]
You may remember me wanting to keep the coolant pre-heater and wanting to make it more effective. Well i mentioned i'd found dt plugs were a very similar size and shape and a little more powerful, these were duly swapped, next up was finding somewhere to put it. It was never going to fit on the gearbox now some bellend has put a couple of turbos up there and i reasoned the closer it is to the heater matrix the more effective it will be. A bit more hacking of coolant pipes, a length of copper piping, taking a drill to the bulkhead (for the 3rd or fourth time that day) and some abuse of the original mount ended up with this:
[attachment=20782]
More to come later, wasting sunshine.
[attachment=20790]
So now i've got to finish it, else they might take the trophy back.
I realised i've been blithely listing items dealt with and not really given any detail on anything, so for anyone interested here is a more complete breakdown of the fabrication work done so far.
The TD05 cold side needed a couple of mounting lugs chopped off for clearance and some sort of tube on the outlet that i can stick a silicone on. Once i'd taken the dremel to it i passed it on to Jim at RH Davey (Daveyboy on the '6 forum) who did this for me:
[attachment=20780]
Jim also welded up the egr outlet on the inlet mani elbow, which we then drilled and tapped for a boost take-off. We didn't have a suitable fitting, so instead we welded two fittings together and wound her in with mole grips.
[attachment=20786]
The GT17 also had a few extra bits of metal that were in the way, so out came the dremel again. As with the td05, i needed a way of getting a silicone to sit nicely and preferably a bead to hang on to, the next pic shows what we came up with. This was one of a few jobs taken on by Emma (other half of samass), hence it being neater than most other bits of the build.
[attachment=20784]
Next up was gauge feeds for the exhaust side - emp and egt. As ever i was too cheap to buy proper fittings, so spent some time with a drill, tap, welder and brake pipe flaring tool. I had trouble finding a suitable flat surface for the screw-in fittings to seal against, so had to come up with alternatives. The egt probe came with fittings, so i opted to use those and when it came to tapping the thread in the manifold deliberately didn't run the tap all the way through. This means the thread is effectively taper-fit and seals nicely when would up tight. The next challenge was where to put it, as you can i was juggling between clearance to the intake mani runners and being able to get a tool to the cut-down exhaust stud nut.
[attachment=20788]
The emp gauge feed is particularly bodgetastic. I felt it would be a good idea to have some sort of cooling between the exhaust manifold take-off and the gauge in the cabin, i had a few old brake line fittings lying around which looked about right for the job. I cut the female end off an old flexi, drilled a hole in the mani piping and welded the bastardised fitting over the top. This meant we could simply make a copper coil from some brake pipe, bang a male fitting on and flare it.
[attachment=20791]
[attachment=20792]
Now i needed a way to get all these gauge feeds from the engine bay through to the cabin. For some reason I seem to have taken the photo before this was introduced to the holesaw, but you get the general idea, the top-left hole is the one we modified.
[attachment=20781]
You may remember me wanting to keep the coolant pre-heater and wanting to make it more effective. Well i mentioned i'd found dt plugs were a very similar size and shape and a little more powerful, these were duly swapped, next up was finding somewhere to put it. It was never going to fit on the gearbox now some bellend has put a couple of turbos up there and i reasoned the closer it is to the heater matrix the more effective it will be. A bit more hacking of coolant pipes, a length of copper piping, taking a drill to the bulkhead (for the 3rd or fourth time that day) and some abuse of the original mount ended up with this:
[attachment=20782]
More to come later, wasting sunshine.