NitroDann's Long Awaited Garage Thread

[NitroDann]

Also the bloody steampipe shop is closed today, so I cant go much further on this job till monday.

Dann

[Jace]

cool sh*t, berry interesting.

[NitroDann]

Lots of photos coming...

Taking forever to upload.

Dann

[NitroDann]

Heres the new collector.
getting to this point is the hardest step, cutting those angles right is bloody tricky, it not just cut and rotate 90*, its more than 90* and varies with collection angle.


Heres how they fit.


2 examples of what the next 4 images are showing.



Inside the collector. Note the fit.





The new collector, and the new collector compared to the other larger collector. It simply isnt possible to fit a big shallow angled collector into this configuration.



Anyone guess where the next pipes go? Cylinders 3 and 4 are pretty easy haha.


Dann

[wozzah1975]

Can't get over the wall thickness in that piccy Dann, I knew the chinese ones were sh*t, but thats thin!

Woz

[NitroDann]

Regular mild steel exhaust pipe is twice as thick.

Dont be fooled by the parts that look thicker on that photo its just the metal shaved over from cutting it, if you know what I mean.

Thats it Woz? not gonna bag me out for the huge merge angle?

Extractors not here yet, hopefully tomorrow.

Dann

[wozzah1975]

Regular mild steel exhaust pipe is twice as thick.

Dont be fooled by the parts that look thicker on that photo its just the metal shaved over from cutting it, if you know what I mean.

Thats it Woz? not gonna bag me out for the huge merge angle?

Extractors not here yet, hopefully tomorrow.

Dann

Mate, I wouldn't bag you about anything. I like the fact that you have a go, and your work looks good

Cheers
Woz

[NitroDann]

I intended to have some new manifold pics up today but it was a long day for a few reasons.

Long story short, I got Patrick Bramston's NA6 to the dyno.

New changes since it was last out and at a dyno (mania) are that I have redone the coolant reroute, ignition system (my toyota COPS) and fitted a new computer (megasquirt 2, with firmware from Gslender himself!) and electronic boost control. And of course it doesnt have the rubbish tune it did have on it (high boost rough running, and it didnt idle, at all) it had a wolf 3d which Im told is quite hard to tune.

Long story short we had a local dyno shop operate a dyno and drive the car with me manning keyboard, and after slowly ramping the boost up and tuning it made over 200rwhp at 5000rpm, and over 250rwhp everywhere about 6000rpm, it is currently set at a lower 8000rpm limit. It hadnt dropped off at 8000rpm, still gaining power.

This power was made at lambda 0.75 (11:1 AFR) and only 13.5 degrees of advance. This is VERY safe.

The car ran out of fuel injectors at this power level running this rich which is fine, as its getting ID1000s (1000cc bosch) and E85 next week.

Without upping the boost and running the same sort of safe tune it will make around 290rwhp due to E85. The plan is to go up another 8-10psi and add another 10* of timing. Total power will come when either the turbo runs out of puff or the 2.5" exhaust becomes a bigger restriction.

Dann

[NitroDann]

So Patrick came and got the car today and it was dríven on the -private track- for the first time.

1st gear is useless.

It roasts 2nd gear like you are in neutral.

3rd gear is wheelspin heaven without touching the clutch.

4th is over by the time you have got your gear change hand back on the steering wheel, and I only used half throttle in 5th gear which still pulled past 180kph at a stomach churning rate. Like still firmly pinned to the seat.

But it drives nicely under 3500rpm just dont let it get past 4k in 2nd at 1/3rd throttle or its game over.

Thats on 17" 225 semi slicks also.


Dann

[NitroDann]

OK here's a manifold coming together today..

Anyone have any suggestions?

Any SE owners seeing any fitment issues? I dont have the car on hand, but by memory, measurements made and internet photos it looks sweet.


Soon to become boost bits!


End of bend crushed into port shape.


Little bit added here.


Cylinder number 4.



Lining up cylinder number 3.


Cylinder 3.



Plans for cylinder 1/2. Thoughts here guys?






Gives you an idea of the flow inside this manifold.


So guys?

Dann

[NitroDann]

The clearance between the cylinder 2 and the cam cover concerns me slightly...

Any input?

Dann

[deviant]

I think that clearance with the cam cover is a concern, look at this thread. There are two good pictures at the bottom of the first post that show the cam cover has a lip sticking out as well as lumpy bits for the bolts..

viewtopic.php?f=57&t=44487

[NitroDann]

I thought so so I changed the design a bit, here it is. this isnt final, nor is it aligned perfectly, just tacked to make sure the design is good.

Infact, any 1.8L guys able to rock up in the next day or so for ten minutes and just have a trial measure?

Thoughts now?










Dann

[Apu]

Mmm...can't wait till you build the other one...and the coolant reroute!

[NitroDann]

Thanks Apu,

Useful feedback anyone?

What would you want changed if it was yours?

Dann

EDIT: come on scott, I know how much time you spend reading in this thread, post too!