CIH Turbo EFI by RallyBob

[RallyBob]

I don't know how I let myself get talked into these things...

7 weeks 'til Carlisle. I have to fabricate an entire turbo system for a CIH Opel, have parts coated and plated, tear-down and regasket an existing engine, install the engine, and dyno-tune it.
We'll see if I even come close.

So, the baseline engine is a Euro 2.0 block with a ported 1.9 head with big valves. I also need to install a smaller cam for use with the turbo (less overlap). I was originally going to use the stock L-Jetronic with larger injectors and a rising-rate pressure regulator, but since that entire system is basically 'stupid' I felt that a stand-alone ECU was the only way to go

Here's what I had to start with:

[RallyBob]

This mess is the stock fuel rail from a 2.0 EFI system. Too much clutter, too small injectors, and just plain ugly.

[RallyBob]

I stripped the intake down, and rough-polished it smooth with various sanding rolls and and an orbital sander. It'll be sent out to the chrome shop next week with some other parts.

[RallyBob]

The new fuel rail I made is made from 3/4" DOM steel tubing. I brazed pieces of flared 5/16" tubing that I cut from the stock fuel rail...these fit into the hose ends of the injectors. Yet to be welded onto the fuel rail in these photos are the AN fittings at the ends for the fuel line inlet and the Aeromotive adjustable pressure regulator.

The injectors are blue Bosch '036' injectors, which flow around 380 cc's at 44 psi. More than enough for the horsepower goals of this engine.

[RallyBob]

The turbocharger I'm using is a stock Subaru WRX TD04 unit. Good enough for 227 hp in a Subaru at 14 psi boost. They're plenty cheap and available, as a lot of WRX owners upgrade to a larger turbo. I see them on Ebay for $100-$200 all the time.

I polished the outside of the turbine smooth in preparation for ceramic coating, and ported the turbine inlet.

[RallyBob]

I started to make the header flange for the turbo manifold. I'm using 3/8" mild steel for the flange with 1.25" cast steel pipe elbows to make the runners. It will be TIG welded together then ceramic coated. It's a lot of work making a flange from scratch...

[GTJIM]

Bob,

I took a correctly sized drawing of the rear disc brake brackets I needed, to a local engineering shop that had a laser cutting set-up.

Before my startled eyes they cut out the brackets in a few minutes - bolt holes and all!

Modern technology has its place.

[tekenaar]

Originally posted by RallyBob I don't know how I let myself get talked into these things... . . . . . . Here's what I had to start with:

So, WHO was able to talk you into this, Bob? Project must have been at least SOMEWHAT interesting to you then, right?

[RallyBob]

Originally posted by GTJIM Bob, I took a correctly sized drawing of the rear disc brake brackets I needed, to a local engineering shop that had a laser cutting set-up. Before my startled eyes they cut out the brackets in a few minutes - bolt holes and all! Modern technology has its place.

Hah! Not here my friend.....

I've had Opel parts made for years including parts that were made via CNC plasma cutter, CNC laser cutter, and CNC water jet. But none of them would look at me for quantities less than 20 pieces, and preferably 50+ pieces. One-offs don't make them any money, therefore they either price it out of sight, or outright refuse to do it. Welcome to America!

[RallyBob]

Originally posted by tekenaar So, WHO was able to talk you into this, Bob? Project must have been at least SOMEWHAT interesting to you then, right?

My good friend Gregg coerced me into trying to build this. It was originally supposed to be just an engine swap prior to Carlisle, but the turbo thing grew out of it.

Why? HP is always interesting...

[oldopelguy]

Originally posted by RallyBob My good friend Gregg coerced me into trying to build this

More like "Gregg got a good look at the parts for another turbo project I had laying around and just had to have one for himself." I know how these things really work, Bob. Wonder what kind of cam he'll be using.....

[Gary]

Rolling, Rolling, Rolling, keep those Opels Rolling.....

[kmon]

Like the fuel rail, and the plenum is going to be purdy chromed, nice work bob. Please more pics as it comes along

[RallyBob]

Originally posted by oldopelguy More like "Gregg got a good look at the parts for another turbo project I had laying around and just had to have one for himself." I know how these things really work, Bob. Wonder what kind of cam he'll be using.....

I'm actually 'de-camming' the current engine by a lot....replacing it with a mild hydraulic cam. .441" lift and 214 degree duration @ .050", with wide 112 degree lobe separation. You'll barely notice it now. No roller cam. Roller rockers of course though.

Bob

[Stressed]

So Bob,

How much does a dream like this cost? Could the owner be heavily involved to learn? I con only dream of this type of project. When it comes to paint, upholstery, or audio, I'm the man, but I usually make things worse when I touch mechanical.

Stressed

[tekenaar]

Originally posted by Stressed So Bob, How much does a dream like this cost? Could the owner be heavily involved to learn? I con only dream of this type of project. When it comes to paint, upholstery, or audio, I'm the man, but I usually make things worse when I touch mechanical. Stressed

You and I need to talk . . . not that I can't do those things, it's just that the "mechanicals" do SO MUCH more for me.

[Stressed]

Sounds good. Unfortunately, I am also cash strapped, and while I believe the cash situation will soon streighten itself out, it will probibly entail a move from the area.

[opelblitz]

I will like to see how the hood will lash down after the intake is placed. I would like to do this to my GT but will have to relocate AC compressor.

Ken

[RallyBob]

Originally posted by Stressed So Bob, How much does a dream like this cost? Could the owner be heavily involved to learn? I con only dream of this type of project. When it comes to paint, upholstery, or audio, I'm the man, but I usually make things worse when I touch mechanical. Stressed

I will likely have a total parts cost next week, as this week I will have everything ordered that I need for the project. There are still a few loose items that will need attending too afterwards I'm sure....there are always last minute incidentals.

Add to this the 'spit and polish' which of course costs more....ceramic coatings, chrome, powder-coating, and then the labor to fabricate.

I work for $50 an hour when it comes to fabrication. At least in this state, that's dirt cheap. Car dealers and repair shops get $65-$72 an hour here, and they aren't building parts, they're just swapping them. Last week I put 17 hours into this project, and that was after my day job. And I didn't work over the weekend....

Bob

[RallyBob]

Originally posted by opelblitz I will like to see how the hood will lash down after the intake is placed. I would like to do this to my GT but will have to relocate AC compressor. Ken

The project car is a 1975 Manta, so no hood mods are needed. But the turbo manifold I'm building will never fit into a GT, there's just not enough room.

Bob

[namba209]

Bob, I know you're busier than a six-pack of mother bears on the Carlisle project, but if and when you take a break, can you e-mail me a list of the 1 1/2 "T" and 90 degree elbows you used on the turbo manifold? I need to get hold of McMaster-Carr and order 4 elbows, 4 "T"s and a pair of 1 1/2 to 2 1/2 reducers. I want to use the exact stuff you did so I can hand polish it like I'm doing my wheels. I just ordered a pair of flanges for the 3.4, I will be able to get them possibly tomorrow. They're 1/2" thick flame cut and I'll get them surface ground before the welding starts. I would appreciate the info, thanx

Ron

[Travis]

Originally posted by RallyBob I work for $50 an hour when it comes to fabrication. At least in this state, that's dirt cheap.

Too cheap! As I've mentioned before, I know of less capable people charging $75/hr and they're fully booked...

-Travis

[namba209]

The average hourly rate for most auto shops here inSANe DIEGO run $100 per hour and over. But what really bugs me about that is the mechs don't get anywhere near that. Then they charge for getting rid of the leftovers from your wheels and also charge for cleaning solvents, etc. It must be the ambiance and the weather

Ron

[RallyBob]

Originally posted by namba209 Bob, I know you're busier than a six-pack of mother bears on the Carlisle project, but if and when you take a break, can you e-mail me a list of the 1 1/2 "T" and 90 degree elbows you used on the turbo manifold? I need to get hold of McMaster-Carr and order 4 elbows, 4 "T"s and a pair of 1 1/2 to 2 1/2 reducers.

IIRC, these are the numbers. You can type them into McMaster's website for more details. I used 1 1/4" pipe fittings, they're actually 1.380" ID.

43425K141 - 90 degree elbow, 1 1/4" pipe, schedule 40

43425K144 - T-fitting, 1 1/4" pipe, schedule 40

They list 1 1/4" to 2", and 1 1/4" to 3" reducers, but none 2 1/2".

HTH,
Bob

[namba209]

Thanx for the info Bob, I noticed they didn't have the required reducers also. I guess I'll have to fabricate something up. It won't be the first time on this mod. I'll be on the phone tomorrow getting the elbows and Ts. I've got a call in to the welder and I'll have him look at the pics and see what it will take to do the deed. I think the flanges will be done tomorrow, I don't know if I got a deal or not, but $40 doesn't seem too bad. They will be surface ground after I get them. It will be good to get back working on the engine again after 8 months of doing little things to pass the time waiting on the other exhaust. Again, thanx for the rapid response.

Ron