Andrew's '93 NA6 - KL V6 swap

[NitroDann]

TIG is definately getting better.

Dann

[Beelzeboss]

Thanks Dann, TAFE is definitely making a difference.

[NitroDann]

What course are you taking?

Dann

[Beelzeboss]

I'm doing Gas Tungsten Arc Welding - Statement of Attainment, it's a 1 year course 4 hours a week. I think it's 1 semester on steel and stainless then 1 semester on aluminium.

http://www.nsi.tafensw.edu.au/Courses/C ... 2012&op=MS

[Beelzeboss]

Well I've finally managed to finish the engine block side of the oil filter relocate. I had to make 3 before I got one which would work

Here's the block of ally I got from the scrapyard for $15. After machining it I'm convinced it's 7075 or some other very high strength alloy. It doesn't machine like regular 6061. It was a complete block, the cut out bit is what I used to make the Mk. I filter relocation block.



Here it is after machining. It took longer than expected because of the high strength alloy.





Unfortunately this one was too long so the AN fittings hit the exhaust pipe. I decided to make a quick and dirty Mk. II from steel just to get the car on the road.



I stupidly made the AN fittings from a piece of 12L14 leaded steel which, as I discovered, cracks really badly when welded. I have a nice hairline crack running right down the middle of each weld.

On to Mk. III I had a piece of 25mm stainless bar for the AN fittings so I bought a 10mm stainless plate from the scrapyard and made this stainless version of the Mk. II.



Here's all 3 together



Here are the AN-10 fittings I'll be using.



On the car.



And here's how the AN fittings will be mounted. There's about 15mm between the exhaust and the fitting, more than enough room for some heat wrap/shielding.







Next weekend I'm on holidays so I'll make up the bracket which holds the oil filter side and make up the lines. Once this is done I should be able to start it. I might have to replace the water temp sensor as it appears to be broken but we'll see. I've booked in to see an engineer on the 8th

Andrew

*edit* if anyone wants me to make an AN-10 weld on bung I'm an expert at it now

[Beelzeboss]

Well, I didn't make my appointment with the engineer One of the injectors has started leaking, the car has an intermittent miss (probably the plug leads, everything else in the ignition system is brand new), and there's still a slow oil leak coming from the back of the engine. I've bought a new rear main seal which is where I think it's leaking and I've started working on a dry sump system to replace the miniature sump it has at the moment. The reason for this is I'd always planned to install a dry sump and now that I have to take the engine out AGAIN I figure I might as well go ahead with it. Also, one or both of the head gaskets are leaking even though they're new I think either the head has warped or the bolts I reused are not doing a good job of providing enough pressure to seal it. White smoke comes out the exhaust and coolant levels drop after running for a few minutes.

Our house is open for inspection at the moment and uni is starting back up this week so I'm going to have to wait until the Christmas holidays to get the car finished. If I have any spare time I'll use it to work on the dry sump pump, sump, and tank.

On the plus side my new oil filter location works a treat and doesn't leak.











And here's a model of the pump I've been working on. It uses two sets of oil pump gears from a Holden 308 to make a two stage scavenge pump with a single outlet.



I'm going to make it from that same 7075 aluminium block I got from the wreckers. It's going to mount where the power steering pump was originally and be dríven by an HTD timing belt, though I still have to design mounts into the pump.

I scored a set of MK. III Supra turbo injectors (440cc) for cheap on ebay which will go in with the supercharger. I figure it's not worth doing ALL this work to swap in a V6 with only 100rwkw, if that, so I'll be making YET ANOTHER MANIFOLD to mount the MP90 charger. I'm still tossing up whether to put a few laminova W2A intercooler cores in the manifold or just going without. I'll only be running low boost (~6 psi) to avoid lunching the gearbox and engine so I'm not sure if it's necessary.

It's a good thing I enjoy working on the car nearly as much as driving it

[username]

Well that's an interesting oil cooler

[A.Chen89]

is that a solid works model and are the gears meshing in the assembly? looks sweet

[Beelzeboss]

Well that's an interesting oil cooler

is that a solid works model and are the gears meshing in the assembly? looks sweet

Cheers A.Chen, it is a solidworks model but I haven't got the gears meshing. They're just fairly rough models to check the fit

[Beelzeboss]

I had a bit of time after uni to work on the pump.

First I cut the big piece into smaller pump housing sized pieces



I tried using the mill with this crazy shell mill to square up the block and bring it to finished size.



It didn't give a great finish and I could only do one at a time, so I busted out this bad boy which I've only used a couple of times before because it's so slow to run and set up.



After AGES setting up and AGES machining, I had three aluminium pump housing blanks



Tomorrow I'm going to try to bore out the housings for the pump gears.

[plohl]

i am so jealous you actually have some machining equipment

Keen to see the scavenge pump done!

Oh, are you still with the fsae team?

[NitroDann]

I have no idea what that second machine is.

Dann

[Beelzeboss]

i am so jealous you actually have some machining equipment

Keen to see the scavenge pump done!

Oh, are you still with the fsae team?

Cheers plohl, yep I'm still with the FSAE team though I really don't get out there often enough because I work on my car so much.

I have no idea what that second machine is.

Dann

It's a metal shaper, not really used in machine shops anymore but very useful for a home workshop (and they're cheap ). One of the only machines which can cut internal keyways and they're very good at cutting splines, dovetails, gears and flattening large surfaces, all with cheap hand ground HSS cutters.

[mrpham]

Love all the awesome machining and cool machines you have

[Gladiator]