Speed's boosted NA6

Cus · Postby **Cus** » Wed Dec 28, 2016 7:48 pm

So it's basically done? You don't need a WG! just wire it closed ;)

Looking good so far!

speed · Postby **speed** » Wed Dec 28, 2016 7:52 pm

Cus wrote:So it's basically done? You don't need a WG! just wire it closed ;)

Looking good so far!

I'm sure there is lots of little things to do like wiring in and set up the boost controller and injector dead times etc but yeah, it's so close I can smell it!

Working this week but have next week off to tap my sump and mod the 2.5 inch exhaust to suit.

Will do a proper post soon and keep posting with each step

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Nevyn72 · Postby **Nevyn72** » Thu Dec 29, 2016 3:42 am

Cus wrote:You don't need a WG! just wire it closed ;)

That could be, ummm....... interesting. :shock:

I'll follow along with the dust-pan and broom to pick up the pieces and take them to the scrap metal dealer! :mrgreen:

speed · Postby **speed** » Thu Dec 29, 2016 7:58 am

Nevyn72 wrote:
Cus wrote:You don't need a WG! just wire it closed ;)

That could be, ummm....... interesting.

I'll follow along with the dust-pan and broom to pick up the pieces and take them to the scrap metal dealer!

Haha. But seriously, I'm keen to see how it compares to yours AFTER a tune ;)

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speed · Postby **speed** » Thu Dec 29, 2016 8:24 am

Mr postman delivered this yesterday.

It's smaller and less fluffy than the other cat.

Whilst I was at work Mrs Speed went to pirtek and purchased a fitting for my sump that connects to the oil drain hose that I have.
She also picked up a stepped drill bit pack.

Then I had to source a 1/4 inch BSP tap whilst everyone is closed for the holidays.
Mitre 10 hope to have it in before the weekend. Fingers crossed!

Once home from work I gave drilling the SS plate another go whilst having a sauna at the same time.

So so close.. and I killed a new drill in the process

Not from speed. Believe it melted a gear under load even though I only had on the slowest setting and gave constant rests and sprayed the hole saw with WD40 as I went.

This weekend I hope to tap the sump, fit dump pipe and go about modding a NB 2.5 inch system to the new cat.
Hopefully the flanges arrive in time!

I've also marked my intercooler pipes for welding and drilled holes for the AIT, BOV and ICV and test fitted.

Re the BOV, I've decided to go for a recirculating 25mm kompact turbosmart.

Hopefully I can find someone that can weld aluminium next week when I'm off work.
Taking suggestions and offers if anyone can help

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speed · Postby **speed** » Sat Dec 31, 2016 4:10 pm

Earlier today I visited Nevyn72.
With his drill press and a new hole saw we went about cutting the centre hole in my wastegate actuator bracket.

It was not easy and took a while to get anywhere. Once we saw daylight in one side, Nevyn72 punched the centre out with a hammer. He then went about grinding down the edges per my scribed markings.

We suspect that the plate is actually hardened stainless and was certainly not easy to work with.

Unfortunately for me the centre hole was still too small and I ended up filing it out with a hand file.

Still needs a clean up but this is what it looks like now.

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smy0003 · Postby **smy0003** » Sat Dec 31, 2016 4:24 pm

Nice work!
Wastegate positioning can be a massive PITA for those of us who don't weld.

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speed · Postby **speed** » Sat Dec 31, 2016 4:32 pm

Still may weld tabs on the sides but considering how tough the plate is I may not need to.

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Nevyn72 · Postby **Nevyn72** » Sat Dec 31, 2016 4:35 pm

speed wrote:Unfortunately for me the centre hole was still too small and I ended up filing it out with a hand file.

Points for dedication on that one mate! :shock:

How long did it end up taking doing it by hand?

Nice to see the final result worked out so professional looking, just give it a little cleanup and polish and you'll be sweet.

speed · Postby **speed** » Sat Dec 31, 2016 4:43 pm

About 30 mins in my sauna.

Did try a file bit from bunnings in a drill but it was useless, so resorted to the hand file.

Will get some more nuts in due course, thanks

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speed · Postby **speed** » Sun Jan 01, 2017 4:28 pm

I didn't have anything planned for today but couldn't just do nothing...

So I pulled out the 2.5 inch NB exhaust that I've had for a while and wanted to see how much work would be involved getting it to fit.

Had to cut off both hangers as they are in different positions on the NA6.

I also had to remove the tail pipe from the muffler.

Without getting the muffler to sit quite low, I couldn't get the clearance I wanted around the diff. This concerned me, especially as I still have the "small" diff in the car.
I mean the muffler is not below the bumber or anything but could be a lot lot higher for a better fit.

I then went to fit the turbo and manifold for the LAST time...

Up until now I've had to remove the 2 lower left studs to get the manifold in and out.
This was far from ideal so I fitted the studs back in and after trying many funky angles and scraping paint from the chassis rail, I finally got it in with all the studs in place.

After I tightened the outside nuts I realised that I needed to loosen them off to get the middle nuts started. Fair enough.

Then when I fitted the hard coolant pipe, I realised that I needed to do the same so that the bracket would fit on without fouling on the manifold. Okay sure.

With the manifold and hard pipe fitted, I proceeded to fit the dump pump.

The hard pipe prevented this and I couldn't remove it from the manifold until I loosened off the manifold bolts again!

With the hard pipe out, I trimmed a piece of the top right of the bracket. I then bent the begeezus out of the pipe, so that it not only cleared the dump pipe but moved it as far away from the heat that I could get it. (Rember a rubber hose attaches to this)

It now sits on the other side of the dip stick and can be removed without having to loosen every manifold bolt. Winning!

Good times

Pics to follow. Crapatalk keeps failing on me.

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speed · Postby **speed** » Sun Jan 01, 2017 4:29 pm

Showing trimed bracket.

After bending the pipe.

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Postby **NitroDann** » Sun Jan 01, 2017 4:46 pm

You can bolt the pipe on, put into the end a rod like a 3/8ths extension and just lever it back and up.

Dann

speed · Postby **speed** » Sun Jan 01, 2017 4:49 pm

Thanks Dann. I actually tried that but couldn't get it to bend easily.
Maybe I should have used a longer extension.

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