CIH Turbo EFI by RallyBob

[tekenaar]

Originally Posted by RallyBob Finished header flange detail. Welded in and out at the flange, and steel washers were added to get to the correct flange thickness, within .002" anyway...

Hey, Bob. Could I suggest lettering your annotations in white (or other background contrast color), so the rest of us could read them . . . please?

[BQS4]

Bob;
You state that you need to get your F.I./Turbo set-up "show quality", LOL, you can leave all the welds as-is, along with all the dirty finger prints (if there is any ) and still blow us all out of the water!

[RallyBob]

Originally Posted by tekenaar Hey, Bob. Could I suggest lettering your annotations in white (or other background contrast color), so the rest of us could read them . . . please?

I should have used lime-green, that contrasts better. But I also made the font a lot smaller than usual so it would fit within the panel size.

All it says, Otto, is '.375" ' at the lower flange, and '.095" ' at the washer I welded in place. That works out to .470" thick. The stock flange thickness is 12mm, or .4724". Close enough for government work....

[RallyBob]

Header merge welded and ground down....

Getting close!

[RallyBob]

The collector cone and flange welded in place. Yes, the manifold is finally done!

[RallyBob]

An overview of the turbo manifold, turbocharger, and intake manifold. Yes, the turbo is close to the intake, however I'd rather have it mounted near the side of the intake rather than under the intake. Heat rises after all...
I will be making a physical heat shield, and also the Swain-tech thermal barrier will reduce the radiated turbo temps by about 300 degrees.

[RallyBob]

A different view....

Got the fuel injection ECU today, so that's the last of the components I'm waiting for. There's still hope for Carlisle.

[Sportwagon75]

Hey Bob - I'm not in that big a rush. It doesn't have to be ready for Carlisle...but please let me know where I can place my order for a duplicate version of what you've got there!!??? -Scott D.

[tekenaar]

Originally Posted by RallyBob A different view.... Got the fuel injection ECU today, so that's the last of the components I'm waiting for. There's still hope for Carlisle.

Which throttle body are you using?

[RallyBob]

The throttle body is from a 1996 Nissan SR20DE. It's 60mm, and has twin TPS'. I just made an adapter to fit it from 1/2" aluminum. I had it laying around the shop, so it was free.

PS, I altered the photo of the header flange for you Otto, I hope it's more visible now. Gotta be sensitive to the needs of our elders.....

[Paul]

Bob, I see from your pic that you are using a Polish Turbo,...LOL

Paul

[RallyBob]

Originally Posted by Paul Bob, I see from your pic that you are using a Polish Turbo,...LOL Paul

Damn, my secret's out.....

Actually I just had so many things going in so many directions I've been relegated to labeling all my parts as they are worked on so they go to the appropriate vendors....heat barrier coatings, chrome plating, powder coating, polishing, etc. Tough to keep them all straight in my head, especially considering my aspirations to get this thing to a certain degree of fit and finish within the time-frame given me.

As much as I would have liked to have thought I was done with the turbo manifold yesterday, I really wanted to finish a few other details such as welding stainless steel nuts to the turbo flange, and performing a bit more porting/cleanup work to the runners and the collector. So those things got completed today.

[RallyBob]

The fuel injection components that arrived yesterday....

[RallyBob]

My alternator of choice for this project, a GM one-wire 80 amp unit. Powdercoated red to compliment the other red powdercoated components that will soon adorn the engine compartment.

[namba209]

O. K. Bob, now the obvious question is: When do you start it up and dial it in? Curious minds would just love to be there for that.

Ron

[RallyBob]

I started with a GM universal upper alternator bracket, which was then cut down and welded to a cut-down stock Opel bracket. I needed to use the curved bracket to keep the GM alternator from hitting the distributor. The stock Opel lower bracket is used, but I have to grind a little bit of the bracket for clearance, and I have my own lower bushings custom made from delrin with a 3/8" ID hole and with the corrected offset for proper pulley alignment.

[BQS4]

Bob;
What is the part # of that alt?

[RallyBob]

Originally Posted by namba209 O. K. Bob, now the obvious question is: When do you start it up and dial it in? Curious minds would just love to be there for that. Ron

The target date for the car owner to get the car to me is two weeks before Carlisle. I will then drop the engine in, wire the EFI harness, plumb the coolant and intercooler piping, make the exhaust downpipe, get it running and tune it for road use, then bring it to my friend's dyno and get it safe to run full boost plus get some hard numbers....

Although originally we had hopes of caravaning a pair of Opels to Carlisle (the turbo Manta and my Ascona wagon), the reality is I will have no time to work on my wagon to prepare it for Carlisle because of the turbo project, and the turbo project is so new I thought it prudent to trailer the Manta just in case there are still bugs to be worked out. In fact, there's always the possibility the car won't even be running for Carlisle, in which case we'll just clean 'er up throw it on a trailer and bring it anyway. But I prefer to hope it will drive onto the showfield under it's own power....

[RallyBob]

Originally Posted by BQS4 Bob; What is the part # of that alt?

In red, it's MGM-7127RSW, it cost $99.95 from Summit Racing. They also have blue, black, orange, purple (Wayne are you listening?), and yellow. The part numbers change accordingly with the color.

[Gary]

Bob, Which car is this going into? Greg's silver one?

[RallyBob]

Yup, this is the one.....

[pvcar]

maybe u could put toghter a parts list on what is needed and part numbers of the diffrent things i would be interested on maybe building a setup for my gt.

[RallyBob]

Won't fit a GT, the manifold doesn't even come close. I thought about trying to put the turbo under the intake manifold, but if it wouldn't fit a Manta, there's no way it'll fit a GT.

Cost? $4600 in parts so far, plus about $2500 worth of my time. But I'm going to make a basic component list for Carlisle for posting on the car's window in a few weeks. But I'm not putting a part number list together, that would take about 10 pages to outline, I had to order parts from 8 different companies!

[Gary]

Originally Posted by RallyBob Yup, this is the one.....

There's the "Best in Show" winner.

[RallyBob]

Originally Posted by pvcar maybe u could put toghter a parts list on what is needed and part numbers of the diffrent things i would be interested on maybe building a setup for my gt.

Since the GT setup would have to be fully custom too, but still different than the Manta, I won't delve into fabrication specifics.

A crude layout:
>Stock WRX turbo, ported turbine
>Stock WRX intercooler, modified to fit Manta
>Stock Opel EFI intake manifold, slightly modified
>Stock Nissan SR20 throttle body, underside modified for fast idle air bypass
>Suzuki motorcycle clutch cable for throttle cable, custom fitted
>Bosch 0-280-150-036 injectors, 380 cc's, 2.5 ohm resistance
>Custom fuel rail
>Aeromotive fuel pressure regulator
>Adapted Griffin radiator, electric fan
>4.75" x 13" Setrab oil cooler, remote oil filter, oil thermostat
>Russel twist-lock fuel and oil lines
>Samco sport silicone coolant hoses with custom aluminum connectors
>2.5" stainless steel downpipe
>Turbo header: all custom made flanges, 1.25" weldable cast steel pipe elbows used to fabricate runners
>Custom made 2" intercooler tubes with silicone connectors
>Compufire DIS-IX ignition with recurved distributor
>SDS EM-4D fuel injection. Optional fuel pump relay, 2-bar MAP sensor (allows up to 14.7 psi boost), fast idle solenoid, and resistors to drive Bosch injectors.
>Turbosmart boost controller
>Surge tank for cooling system
>Re-engineered crankcase breather system
>80 amp alternator
>Custom built heavy duty clutch
>Steel oil pan with turbo drain-back tube welded in
>Custom sealed cold air box and remote filter

As you can see, most of these items are custom, so they'd have to be built for your application, and my specs would not apply.

After working on this project for a few weeks, I've rethought the engine I'd like to build for my father's GT, and rather than build a N/A 2.7 litre, I think I'll go with a 2.6 litre turbo EFI engine instead. So if you can wait a year or two, I'll have specs on building that particular engine for a GT. I know it'll have a ball-bearing GT28RS turbo....that's as specific as I've figured the project out!

Bob