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Old 01-10-2008
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Turbo GT

After 3 years I have finally got my fuel injected inter cooled turbo on the road. Those who said there is not enough room under the GT hood are wrong. Of course you have to be willing to design and fabricate your own manifolds. The turbo is out of a Saab as is the inter cooler. The EFI is sold by Weber Red Line.
Roger Wilson built the motor with a 1/2 inch stroke, Venollia pistons, and Crower long rods. He also used his ported and polished big valve head with Isky cam and roller rockers fixed by GTJIM. What started out as a cheep junkyard turbo project snowballed into a no budget marathon. I have CAD files on the manifolds if anyone is interested.
Attached Images
File Type: jpg engine bay right.jpg (162.9 KB, 500 views)
File Type: jpg exhaust and turbo.jpg (145.1 KB, 388 views)
File Type: jpg engine left.jpg (134.1 KB, 366 views)
File Type: jpg intake.jpg (141.2 KB, 378 views)
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Old 01-10-2008
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WOW!!! Drool!!!

Mike

P.S. Welcome to the site.
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Old 01-10-2008
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So I take it this is not a cold weather car, I don't see a heater. What is the turbo lag like? What was the estimated cost? The CAD files would be great to see.

If you have the time, a write up with play by play pictures would be great.
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Old 01-10-2008
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Originally Posted by californiagting View Post
After 3 years I have finally got my fuel injected inter cooled turbo on the road...
WOW is right. Nicely done! I've see other turbos on 1.9s (I actually owned one for a while) but mostly on carbs. What kind of boost are you seeing with the Saab setup?
Ron in Indy
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Old 01-10-2008
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You are right the heater is not hooked up. In Southern California the only problem you have with an old Opel is that the car is too hot inside. I put double 1/4 inch foam with foil backing just to lower the heat inside the car. I also built heat shields for both the exhaust manifold and the intake because a turbo makes so much heat. The heater is still there if I want it but I want to air condition the car before I heat it. The temperature a home today is 68 F.
The waste gate is set for 6 lbs. right now but I hope to raise it to 10 lbs.
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Old 01-10-2008
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More like a Double Wow, I think.
Nice work!
Hey, no fair, how come I didn't get a "Power by Roger Wilson" sticker?
That's gotta be a collector's item now, ya know.
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Old 01-10-2008
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Glad you got it running and shared some photos. Roger had spoken to me for a long time about this project and I was hoping to see it some day!

Bob
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Old 01-10-2008
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The Saab turbo is a Garret t-25 model. It is designed for street cars not drag cars. The boost is maxed out at 6 lbs. at 1500 RPM. Needless to say there is NO turbo lag. I told Roger I wanted a torque monster so thats what I got. It pulls like crazy from 2000 to 5300 RPM after that the turbo restricts air and the engine goes flat. I put the sticker on the valve cover because this is supposed to be Roger's last motor for anyone other than himself.
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Old 01-11-2008
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Congrats Ralph
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Old 05-10-2008
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Talking Sweet!!

Hey how many horses are pushin out that thing?
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Old 05-11-2008
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I have to agree with above.WOW.That looks great
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Old 05-15-2008
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What are you using for ignition? I dont' see a dizzy...
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Old 05-16-2008
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Thanks for your comments. The Red Line ECU can use the stock Opel 2.4 crank pulley. It is completely programmable so you can advance or retard ignition by mapping RPM, Boost, throttle position, or air temp. I do not know what the horsepower is but I hope to dyno it soon. I have a picture of the exhaust with turbo. No cutting required but I did remove the air filter mount.
Attached Images
File Type: jpg exhaust and turbo.jpg (121.4 KB, 129 views)
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Old 05-16-2008
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Originally Posted by californiagting View Post
Thanks for your comments. The Red Line ECU can use the stock Opel 2.4 crank pulley. It is completely programmable so you can advance or retard ignition by mapping RPM, Boost, throttle position, or air temp. I do not know what the horsepower is but I hope to dyno it soon. I have a picture of the exhaust with turbo. No cutting required but I did remove the air filter mount.
Nice work very nice.
What if I can come close to the real numbers without the help of a dyno.
Humm might be a good test of the software.

Last edited by wrench459; 05-16-2008 at 10:58 PM.
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Old 05-28-2008
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Originally Posted by californiagting View Post
I have CAD files on the manifolds if anyone is interested.
I am interested. Can you post them on the forums so everyone can access them?
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Old 4 Weeks Ago
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I am also interested in the Cad files
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Old 4 Weeks Ago
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If you want to see what the manifold will look like just print out the drawing and tape it together. I made the manifold out of 3 X 2 x 1/8 wall tubing. I taped the pattern to the tubing and cut it out with a 4 1/2 inch angle grinder. Strictly low tech equipment. The flanges were cut on a laser cutter at a local sheet metal shop. A little bending and welding and half the turbo project is done.
I have changed the turbo to a ball bearing T-28. It is much larger but still fits. I had to lose the heat shield. Also I added a Saab waste gate controller so my computer can control the amount of boost before the waste gate opens. I now limit myself to 15 lbs.
Attached Images
File Type: jpg exhaust 1.jpg (54.4 KB, 39 views)
File Type: jpg exhaust 2.jpg (53.5 KB, 36 views)
File Type: jpg exhaust 3.JPG (149.4 KB, 31 views)
Attached Files
File Type: eps opel turbo exhaust.eps (12.5 KB, 7 views)
File Type: pdf opel turbo exhaust.pdf (16.4 KB, 10 views)

Last edited by californiagting; 4 Weeks Ago at 01:47 PM.
  #18 (permalink)  
Old 4 Weeks Ago
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Now for the intake manifold. Again I recommend cutting and taping a print out first. The intake manifold is a lot more involved. I took my design to the laser cutter and he decided that he would cut it out of stainless steel. I can not weld stainless so he welded it for me. Only charged $100. The injector bungs I bought from simple digital. I used a throttle body from a Chevy. It uses a 2 bolt mount. If I did it again I would find a 4 bolt throttle body. I changed to a fuel rail system just to clean things up. The lines from the manifold are for the brake booster and assorted devices.
Attached Images
File Type: jpg intake 1.jpg (64.8 KB, 30 views)
File Type: jpg intake 2.jpg (54.5 KB, 29 views)
File Type: jpg intake 3.JPG (160.5 KB, 32 views)
Attached Files
File Type: eps Opel intake FI.eps (18.7 KB, 0 views)
File Type: pdf Opel intake FI.pdf (23.2 KB, 1 views)
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