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IMPORTANT: enter the case-INsensitive alphabetic (no numbers) code AND WRITE SOME SHORT summary of changes (below) if you are saving changes. (not required for previewing changes). Wiki-spamming is not tolerated, will be removed, so it does NOT even show up in history. Spammers go away now. Visit Preferences to set your user name Summary of change: ==== Turbo conversion progress story: ==== I started out with [http://www.squirrelpf.com/msavr/files/ctiturbon60n.jpg a lot of tubes]. The 2 to 1 collectors were crafted by the pipe shop, they also supplied 12 x 90 degree bends and 2 meters of straight pipe. I cut he collectors to their minimal length [http://www.squirrelpf.com/msavr/files/ctiturbon62n.jpg and fitted them to the engine flange with some masking tape]. After that i started working on the [http://www.squirrelpf.com/msavr/files/ctiturbon66n.jpg 4 to 1 collector] which turned out pretty nice. With [http://www.squirrelpf.com/msavr/files/ctiturbon73n.jpg the new tig welder] i began my first tig welding job; [http://www.squirrelpf.com/msavr/files/ctiturbon68n.jpg welding the collectors to the engine]. The tubes were fitted to the engine using some masking (and other various types of) tape, results of these actions can be viewed [http://www.squirrelpf.com/msavr/files/ctiturbon72n.jpg here] and [http://www.squirrelpf.com/msavr/files/ctiturbon74n.jpg here] Great progress during the weekend, welded up the entire manifold, unfortunately i did not have the camera available, so i can just show the final results ([http://www.squirrelpf.com/msavr/files/ctiturbon75n.jpg welded_manifold#1], [http://www.squirrelpf.com/msavr/files/ctiturbon76n.jpg welded_manifold#2]). After cutting the nose cone i made the tiny pipe beteen the collector and the turbo flange, results here: ([http://www.squirrelpf.com/msavr/files/ctiturbon78n.jpg welded_manifold#3], [http://www.squirrelpf.com/msavr/files/ctiturbon79n.jpg welded_manifold#4]). '''02/03/2004''': Got the manifold back, i could not reach the inside of the collector with the torch, had it welded at the pipe shop. I welded the pipe, which was mated to the flange and collector, in place. [http://www.squirrelpf.com/msavr/files/ctiturbon84n.jpg It looks pretty impressive] '''16/03/2004''': The last week few weeks have been really busy, i've welded the clutch pulling handle ([http://www.squirrelpf.com/msavr/files/ctiturbon89n.jpg pic]), flattened the back of the manifold and grinded the rough edges from the ports. Assembled the rest of the engine and fitted the flywheel, clutch (pressureplate) and gearbox ([http://www.squirrelpf.com/msavr/files/ctiturbon88n.jpg pic]). The engine is ready to be fitted to the car ([http://www.squirrelpf.com/msavr/files/ctiturbon91n.jpg pic]). After pulling out the 'make-things-fit-engine' i cleaned out the entire motor area you also get a nice view of my uprated suspension (i used to have the 1.6 gti type). '''16/03/2004 - 21:36''': Fitted the engine tonight, [http://www.squirrelpf.com/msavr/files/ctiturbon93n.jpg it looks sweet] !!! '''25/03/2004''': Engine has been in for a while now, but no start yet, its getting close though. I've cut the downpipe flange to shape and picked up the 60 mm id pipes. Unfortunately im out of gas for the welder (good excuse) so the downpipe will have to wait for a while. Great progress on the engine loom going to the dash, its done and verified. The [http://www.squirrelpf.com/msavr/files/ctiturbon101n.jpg peugeot s16 coils] came in today, with a little persuasion they will be mounted like [http://www.squirrelpf.com/msavr/files/ctiturbon97n.jpg this] '''18/04/2004''': My v3 came in friday, yes!! did a lot of soldering the last few days. Decided to fit the v3 in the case that used to house my oem ecu. After some remodeling it fitted very nicely, [http://www.vems.hu/files/DaveBrul/ctiturbo%20(102).jpg picture of todays work]. Back again, sorted out the [http://www.vems.hu/files/DaveBrul/connector_pinout.xls connector pinout], and did some work on my [http://www.vems.hu/files/DaveBrul/config.txt config.txt], [http://www.vems.hu/files/DaveBrul/tables.txt tables.txt] and [http://www.vems.hu/files/DaveBrul/my_make my_make] '''26/04/2004''': Lots of wbo2 circuit testing / debugging the last week, some pics of the results [http://www.vems.hu/files/DaveBrul/ctiturbo%20(103).jpg pic#1] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(104).jpg pic#2] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(105).jpg pic#3] '''07/05/2004''': Finally the gas has arrived. Put it to use and welded most of the downpipe: [http://www.vems.hu/files/DaveBrul/ctiturbo%20(106).jpg pic#1] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(107).jpg pic#2] '''11/05/2004''': It runs!! *happy face* pictures of the (almost) finished engine: [http://www.vems.hu/files/DaveBrul/ctiturbo%20(108).jpg pic#1] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(111).jpg pic#2] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(112).jpg pic#3] '''12/05/2004''': Proof, two movies of the engine doing some humming [http://www.vems.hu/files/DaveBrul/ctiturbo_start.avi movie#1 starting] [http://www.vems.hu/files/DaveBrul/ctiturbo_run.avi movie#2 run] '''15/05/2004''': More movies [http://genboard.mine.nu/~dave/ctiturbo_demo.avi #1] [http://genboard.mine.nu/~dave/ctiturbo_demo2.avi #2] '''18/05/2004''': Welded a nut to the downpipe for the wbo2 sensor [http://www.vems.hu/files/DaveBrul/ctiturbo%20(115).jpg pic#1] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(118).jpg pic#2] '''23/05/2004''': Tonight the car will be ready for a short testdrive, this is what it looks like now: [http://www.vems.hu/files/DaveBrul/ctiturbo%20(124).jpg pic#1] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(125).jpg pic#2] '''30/05/2004''': Drove a few km today, made a [http://www.vems.hu/vems.hu/files/DaveBrul/testrun2.xls logfile] of the drive, you can use the [http://www.vems.hu/files/misc/mslvv225b5.zip logviewer] to view the log in a grapichal manner '''31/05/2004''': some pictures showing the DR = 22 flyback [http://www.vems.hu/files/DaveBrul/ctiturbo%20(121).jpg #1] [http://www.vems.hu/files/DaveBrul/ctiturbo%20(122).jpg #2] and [http://www.vems.hu/files/DaveBrul/ctiturbo%20(132).avi a movie of me driving the car back into the garage] (the interesting stuff happened before that (check the logs above :) ) '''01/06/2004''': measurement day, i build a test rig to measure the injector opening time with scope. To do so i connected a 0.1 Ohm current measuring resistor in series with the injector and (with scope) measured voltage across it. Made a few screenshots: [http://www.vems.hu/files/DaveBrul/injector_opening.jpg a low voltage (11.7v) table setup without fuel pressure] and [http://www.vems.hu/files/DaveBrul/injector_opening@3bar.jpg a test in car with 3 bar fuel pressure and 13.8v battery voltage]. The resulting injector opeing time proved to be 1.36 mS for my highZ injectors. [http://www.vems.hu/files/DaveBrul/injector_pulse.jpg A complete injector pulse with flyback voltage can be found here] '''10/06/2004''': Results of last weeks work: [http://www.vems.hu/files/DaveBrul/ctiturbo%20(126).jpg changed coolant container to a compact volvo item], and fitted a [http://www.vems.hu/files/DaveBrul/ctiturbo%20(127).jpg later type valve cover] (i has cut-outs for the cop coils). '''29/06/2004''': Another test drive, this time some nicer movies. I fitted an other iat sensor (open-cage-type) and connected the turbo watercooling. Movies: [http://www.vems.hu/files/DaveBrul/MVI_0022.avi #1] and [http://www.vems.hu/files/DaveBrul/MVI_0023.avi #2] also a [http://www.vems.hu/files/DaveBrul/datalog198001030024.xls datalog of the drive] [http://www.vems.hu/files/DaveBrul/IMG_0024.jpg Picture of the engine in its current state] '''03/07/2004''': As expected, the standard air filter hoses could not deal with the boost pressure, after fixing a split hose for the third time, i decided it was time to upgrade to some boost resistant hoses with thin walled steel pipe in between. Result of a few days work can be seen here: [http://vems.hu/files/DaveBrul/ctiturbo%20(132).jpg engine] [http://vems.hu/files/DaveBrul/ctiturbo%20(133).jpg engine inlet closeup] '''05/07/2004''': Drove around with the new pipes today, the logfile of the drive can be found here: [http://www.vems.hu/files/DaveBrul/log05072004.zip log05072004] '''06/07/2004''': [http://www.vems.hu/files/DaveBrul/datalog06072004.zip Another logfile], took the car for another spin :) '''29/09/2004''': The car spend some time on the dyno today with impressive results: [http://www.vems.hu/files/DaveBrul/mi16dyno.jpg 263.3Hp @ 6821 rpm / 336 Nm @ 4825 rpm]; more proof: a [http://www.sci.fi/~charly/temp/dave/mi16dyno.avi video of the dyo run] and [http://www.vems.hu/files/DaveBrul/dyno.xls a datalog of the dynorun] '''31/01/2005''': The saga continues! I'm sourcing a bigger turbocharger Holset HX-40 is on the list, does anyone have flowmaps of this turbo? ---- Back to MembersPage/DaveBrul Optional: Add document to category: Wiki formatting: * is Bullet list ** Bullet list subentry ... '''Bold''', ---- is horizontal ruler, <code> preformatted text... </code> See wiki editing HELP for tables and other formatting tips and tricks.