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Wink
02-20-2006, 01:40 PM
I started welding my rear manifold for the install of my twin turbo install. Let me tell you this....... I'm by no means a welder at all. :(

The welds looke like birdshit. But they penetrate all the way through to the other side without undercutting the outlying material.

I'll get pics up when I get another spool of welding wire and complete the main welds of the manifold.

http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000514.jpg
http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000513.jpg


As soon as I pick up more welding wire, I'll complete the initial welds. Then add the radius adapter and turbo flange.


Got the wire and new tips this afternood. So I finished the initial welding prior to cutting/welding for the turbo flange. Here you get a really good idea of my birdshit welds that will hold like a mutha.

http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000515.jpg
http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000516.jpg

Don't dispare about the welds on the flange mating surface. I will machine the mating surface flat when I have the time.



Wink

BadAssPerformance
02-20-2006, 04:17 PM
not bad for not being a welder :thumb:

Ondonti
02-20-2006, 06:32 PM
Good thing I slapped you around.

Twins FTW (For teh win).

What kind of welder?

Wink
02-20-2006, 07:08 PM
Just a cheap Campbell Hausfield WF1800, 70 amp flux-core welder.


And I was only thinking of a single due to the installation factor. But I think I'll get better performance from the twins since I'm staying under 15 psi boost for this car.


Thanks for the backhands!!!!!:whip:

GLHS592
02-20-2006, 07:22 PM
I'm a decent self taught welder. I sure couldn't weld that nice with a flux core.

Ntrain2k
02-20-2006, 08:00 PM
We call those gorilla welds around here.......

Ugly, but strong as hell........

2.216VTurbo
02-21-2006, 02:02 AM
Nice, but wont it hamper flow by not having an exit?:lol:

Wink
02-21-2006, 08:17 AM
Nice, but wont it hamper flow by not having an exit?:lol:



Ahhhhhh

Good eye, Grasshopper.

I'm going to be cutting the manifold and adding the turbo flange today, hopefully.

Wink
02-25-2006, 02:51 PM
More progress completed today. :thumb:

Enjoy!!!


http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000519.jpg
http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000518.jpg
http://i5.photobucket.com/albums/y169/mwinkle353/The%20Headless%20Horseman/Turbo%20Project/IM000517.jpg

Stevien1
02-26-2006, 12:48 AM
They look pretty good for a 70amp flux core welder! You'll probably spend more time grinding all the slag off than it took to actually weld the thing! ;)

-Chuck James

93sundance
02-26-2006, 11:59 AM
:clap2: keep up the good work winkman.

3rdGen3.0
02-27-2006, 12:33 AM
probably would have been more complicated, but i would have went with individual runners... air flow is going to be quite turbulent in that manifold...

either that or a log setup with the turbo on the end...

Dave
02-27-2006, 11:37 AM
Not bad Wink! Can't wait to hear more about this beast. Are you still going to be using those turbos off the Ford Probes?

Ondonti
02-27-2006, 01:34 PM
airflow shouldnt be that bad. 3000gt's seem to make 500awhp like its no problem using manifolds that look similar to that. Sometimes easy fitment is king.

Wink
02-27-2006, 05:42 PM
Not bad Wink! Can't wait to hear more about this beast. Are you still going to be using those turbos off the Ford Probes?


Yup, the turbos are the IHI RHB5's from Ford Probe 2.2L turbo motors. They seem to be the best matched turbo for my needs. The fact that they're cheap is another bonus. And if you can find the proper flanges, like I did, mounting is really simple. Since the inlets are 1.75" inside diameter. Everything is posted on my cardomain page. I usually update that with every step of the turbo build.

Wink
02-27-2006, 05:50 PM
probably would have been more complicated, but i would have went with individual runners... air flow is going to be quite turbulent in that manifold...

either that or a log setup with the turbo on the end...


That's a great idea. But I really don't care about building a 700+hp monster. The turbulence that may be inside my style manifold won't matter a hill of beans to what hp numbers I'm expecting to attain from it. The object of my build is to make a quickspooling, streetable turbo setup that will be able to net me between 330-400 at a max boost between 14-18 psi. My normal boost probably won't go over 10 psi for street trim. And that will be more than plenty hp for it's intended use.

Now, if I were building a race motor with a setup like this, I'd use Garrett T3 turbos with a 50 trim compressor on each side. And mate them with a manifold you have suggested. But the engine bay would be stripped of everything but the motor and trans. And that would allow for an equal length runner header setup.

But for me, this will work just fine.



Don't hate until I post the power numbers.

Ntrain2k
02-28-2006, 07:25 AM
Don't hate until I post the power numbers.

:thumb: :thumb: :thumb:

dodgeshadowchik
02-28-2006, 09:40 AM
looking good wink! i can't wait to see how the car performs!! i thought about twinning my car...but i'm having enough problems with fitting a single turbo.. LOL!!

93sundance
02-28-2006, 04:21 PM
Im just gonna stick a big --- turbo on mine.....someday hehe. Unless I find a better job, then I'll do it ASAP.

93sundance
02-28-2006, 04:22 PM
of course I'm not talking about my 10:1 compression motor

3rdGen3.0
03-02-2006, 01:17 AM
turbo is on the to-do list for me as well... twins would be nice, but i'd put them on the end of a log manifold...

well done, though, wink... i'll be looking forward to seeing the finish of this

Frank
03-02-2006, 08:12 AM
As a word of advise...

Even though you will grind the welds away AND the flange was flat, you still need to take it to a machine shop. It needs to be perfectly flat. If it is not, then you will develop exhaust gas leaks and such. This is from past experience of others.


Frank

Wink
03-02-2006, 12:50 PM
As a word of advise...

Even though you will grind the welds away AND the flange was flat, you still need to take it to a machine shop. It needs to be perfectly flat. If it is not, then you will develop exhaust gas leaks and such. This is from past experience of others.


Frank


Both flanges will be milled flat on a machine. I didn't intend to grind them myself. Duely noted information tho. Thanks.

Frank
03-02-2006, 03:38 PM
Sweet!

Irocelectric93
03-27-2006, 12:17 AM
All this talk of turbos is getting me anxious.

3rdGen3.0
03-27-2006, 01:44 AM
All this talk of turbos is getting me anxious.

Me as well... end of this summer is my goal...

Wink
03-30-2006, 01:06 PM
Me as well... end of this summer is my goal...


Patience Grasshopper.....


The funny thing about mine is that I started the ball rolling on a turbo project in 1999. It wasn't util last year I had most of the parts for the setup. And Brent can vouch for this next statement.... I've changed my mind about my setup at least a dozen times since it's beginning. This was mainly due to the lack of information about the turbos I've had in hand. But now I've got good compressor maps on thise. Now I have no doubts that these turbos are exactly what I've been wanting for the twin setup.

Last year, the project was put on hold due to the wife being in the hospital and out of work. But this year, she's doing much better and working again. That's why I finnaly got started on my rear manifold. And now I have to complete the setup this year, come hell or high water. Cause I don't want to have to take all my stuff with me when I move.

Long story short, do lots of planning in the beginning, or you will wind up spending too much money or time on the actuall processes.

Wink
03-30-2006, 02:55 PM
Got some more done with the rear manifold today.

I blended the inside welds of the 2" square adapter to better funnel the exhaust gases out the round port of the turbo flange.

http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_54.jpg

93sundance
03-30-2006, 03:57 PM
:thumb:

Ondonti
04-01-2006, 04:42 AM
and when wink moves we will be best turbo friends being only a state away from each other ;)

Wink
04-01-2006, 03:12 PM
Oh hell yea!!!!!!!


I somehow think our two cars will get a lot of recognition once we get them totally completed.

Irocelectric93
04-01-2006, 08:00 PM
Hate to break it to you guys but brents car already has quite a bit of recognition...anyone wanting to turbo a 3.0 has taken a look at his setup. And wink...your setup sounds nuts i can't wait to see it.

3rdGen3.0
04-03-2006, 06:38 PM
make sure your holes in the manifold are slightly larger than the stud on the heads...

i've been reading up on turbo systems lately :)

Wink
04-04-2006, 07:08 AM
make sure your holes in the manifold are slightly larger than the stud on the heads...

i've been reading up on turbo systems lately :)




I'm one step ahead of you on this. But, thanks for the heads up.

Ondonti
04-05-2006, 03:03 AM
Roger is moving to Utah, we will have a Rocky Mountain party :P

Wink
04-06-2006, 05:59 AM
sounds good to me!!!!!!!!!!!

Wink
05-06-2006, 10:31 PM
Made some more progress today on the twins. I started on the front manifold adapter. So far I've been able to cut the elbow and weld it to a suitable flange that will mate it to the stock front manifold. I still need to lay a bead on the mating surface of the flange and clean up the welds. Then I can weld on the turbo flange. From what it looks like, the turbo will fit perfectly between the front valve cover and the battery. I may have to ditch the stock radiator fan for a thinner unit, because the elbow I have for the turbo's inlet is 3" from edge to end, and I only have 2.75" of room. Lucky for me I'll have solid motor mounts.



Now, if I can only find that darn digital camera.......


I hate it when the wife moves things around on me without letting me know.



Found the camera.....


http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_55.jpg

Ondonti
05-09-2006, 03:36 PM
Just smash some of the fan off with a hammer. My fan seems to shrink every time I installed a new motor this last winter. :p

Wink
05-10-2006, 12:02 PM
Front manifold/turbo adapter is 80% completed now. I just need to surface the flanges and clean up the welds.


http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_56.jpg

Wink
05-12-2006, 05:04 PM
Mounted the manifolds and a pair of mock-up turbos to the spare motor in the shed. Bare with me on the photos. There's not alot of room in the shed for great photo opportunities.


http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_57_full.jpg
http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_58_full.jpg
http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_59_full.jpg
http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_60_full.jpg



Trust me, the turbos I'm using will be properly clocked for decent oil drainage and compressor outlet positions. These are just to help me mock up the downpipes. Oil lines will be run after I get the turbos I'm going to run reclocked for proper orientation.


Wink

mcsvt
05-12-2006, 07:57 PM
Lookin good :thumb: Glad to see the progress lately :)

Wink
05-13-2006, 11:05 PM
Yea, too bad the rear manifold isn't going to work.

Sits the turbo too far back. about 1-1.5" too far.

So, now I have to build another manifold of another design. Hopefully I will pull it off with my new plans.

I'm going to move the turbo runner closest to the transmission. And angle it tighter against the valve cover. I'm hoping to get about 1/4-1/2" of clearance between the valve cover and the wastegate actuator arm. That way I should have the necessary clearance to install it without messaging the firewall much.

Wink
05-21-2006, 02:56 PM
Started a new rear manifold design this week. So far it's going "fairly" well. I think I mangled two of the elbows trying to miter them with a grinder with cutoff wheel. maybe I'll just get a couple more and send them to a machine shop for proper cutting. But at least you can see what I have done so far, and get an idea of the new design.

http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_61_full.jpg
http://memimage.cardomain.net/member_images/12/web/252000-252999/252407_62_full.jpg

Whorse
05-21-2006, 06:29 PM
Those look awesome. Can't wait to see the measurements.

mech1nxh
05-22-2006, 12:20 AM
doesnt look to "mangled " to me...quite the contrary...just a prototype!!!!!

mcsvt
05-22-2006, 09:06 AM
Lookin good Wink. Glad your not giving up :D

Wink
05-22-2006, 11:34 PM
doesnt look to "mangled " to me...quite the contrary...just a prototype!!!!!


Well to me they are mangled. If you look closely at the one pic, you can see a huge gap between the two elbows. I really botched up that angle of those. But I'm going to put them on the belt sander to try and flush them up a bit more. If that doesn't work, then it's off to purchase another pair of elbows and take them to a machine shop that has a band saw with the proper vise to get me the proper fit.

Ondonti
05-23-2006, 01:53 AM
bah, just fill it with a pool of metal ;)
Put a piece of metal in the middle so it doesnt leak through, then grind out the inside to smooth it out again.

Whorse
05-23-2006, 02:25 AM
could try building it up with welding beads and trying it as a prototype. Either way it looks promising.

BoostMonkey
05-30-2006, 02:17 AM
Holy Cow! Those are great! But I got to ask man, where in the hell do you buy those exhaust elbows? Could be quite handy for a future boosted /6 project!

Michael

Wink
05-30-2006, 02:35 AM
I get my elbows and tee fittings from McMaster-Carr.com



1.5" schedule 40 mild steel butt weld pipe fittings.

Bardo
01-03-2007, 09:41 PM
so what happened

mpgmike
03-09-2007, 11:23 PM
Your welding is functional. That's what counts. I see your ruler with "Anderson Creek Emergency Services 911". You weren't welding in the living room again were you? ;)

Mike

Whorse
03-09-2007, 11:31 PM
I was just thinking about Wink's project today. Any updates on this, or on your paint job?

Ondonti
03-10-2007, 07:25 AM
Wink has life to deal with right now :(

TurbododgePirate
03-14-2007, 12:25 PM
Wink, Just as an idea..... my 2001 SAAB 9-5 turbo has a turbo on the front 3 cylinders, and not on the rear... the rear 3 just goes via Y pipe into the rest of the exhaust. Now it isn't a high boost application, but the car does have 200 hp and 230 ft/lb of torque. Additionally a reprogrammed computer can get me 240 hp and 300 ft/lb of torque.

Anyway, I just thought I would throw that out there. ~~H

Wink
03-20-2007, 01:12 PM
Wink has life to deal with right now :(



Unfortunately his statement is very true.

I'm dealing with a pending move, a bitter and expensive divorce, and more hours at work. Unfortunately, I may not be able to finish this project. I guess I'll figure it out after the divorce is final. Money and time has a lot to do with it.

Wink
04-09-2007, 07:47 AM
Well all,

The twin turbo project is offically dead for the lebaron. It's time for me to move on to a bigger and better things.








Can anyone say, "Twin turbo 3.0L minivan?"


Well, that's the plan for now anyways.

The lebaron is going to be replaced by a minivan, probably within the next few months. I require a much larger vehicle. And as much as I dispise the 'agility' of a minivan, it will be of more use to me than a convertable is at the moment. However, a fast minivan is more depressing to loose to than a 2 door vehicle, if you're driving a fast ( I use this term loosely) V8.

Anonymous_User
04-09-2007, 08:08 AM
Whatever vehicle you are building, its just good to see you building something after dealing with life.

Wink
04-09-2007, 06:45 PM
Well, I looked at a van today. It has power NOTHING. But that's ok by me. The motor runs smooth and only has 78k original miles on it. The interior looks as if it just came off the show room floor. The exterior has one minor ding on the fron passenger fender. And the same corner's lens assembly is broken. Not a lick of rust on the body. The only major issue is that it needs a transmission. The best part is that I should be able to get it for under $500, with another used transmission.

Devsdaytona
04-10-2007, 12:37 AM
5-speed:eyebrows:

Wink
04-10-2007, 11:19 AM
Not just yet.

Today I went JY shopping, and found a 604 for a good price. And we've agreed upon a price for the van. He's willing to sell it to me for $350 + transmission. And he'll help me swap out the transmission.

I just can't pass up on a deal like this.

However, in the future, after I get the twin turbo setup completed, I may attempt a 5 speed swap into this vehicle. But my heart is telling me just to stay with the automatic. I, for some reason, see a race built 670 with a reverse manual valve body and a Hurst or B&M slap shifter in the future for this van.

mcsvt
04-10-2007, 12:36 PM
:thumb: Sounds like a nice deal. Keep forgetting to log into Yahoo...

Dave
04-10-2007, 03:28 PM
Trust me Wink, you wont regret buying a van. :nod: If it helps any you've given me a lot of motivation to buy a 3.0 Van and do things to it that I wouldn't do to a farm animal. :thumb: Erm, turbo wise that is.

Wink
04-11-2007, 08:07 AM
I got the new (used) trans yesterday, plus new fluids/filters/seals/sensors. Today, I embark on the task of swapping out the transmissions. Wish me luck.

2.216VTurbo
04-11-2007, 11:24 AM
I got the new (used) trans yesterday, plus new fluids/filters/seals/sensors. Today, I embark on the task of swapping out the transmissions. Wish me luck.

I am glad to see your back into this little hobby of ours, you have some cool projects and great posts:) Life does get in the way sometimes:o

Wink
04-14-2007, 11:01 PM
Well, the transmission lasted all of 60 miles before it gave up the ghost. Glad I tried to drive it a day or so before embarking on a long trip (with lebaron in tow) back to NC. That could have been disasterous.

Anyway, I've decided to keep the van. But I've left it in the capable hands of my father's mechanic. He's going to take the original transmission to a reputable transmission repair shop and have a complete rebuild done on the unit. Then he's going to have the whole van looked over and fix anything that will be required to have the van inspected. Unfortunately, I won't be able to pick up the van for another month or two. But when I do, it'll be ready for me (new/rebuilt transmission and all).

Wink
04-17-2007, 12:17 AM
Trust me Wink, you wont regret buying a van. :nod: If it helps any you've given me a lot of motivation to buy a 3.0 Van and do things to it that I wouldn't do to a farm animal. :thumb: Erm, turbo wise that is.

Oh, I've got some good ideas for this van already!!!!

Something is telling me, with all the under hood room it has, a T4 will fit quite nicely. And in the most inconspicuous location too.:eyebrows:

Wink
05-11-2007, 03:18 AM
Transmission is done!!!

My dad drove the van for me today, and said it was smoother than his 2007 Nissan Altima's transmission. Power comes in really smooth, or so he says. But he had concerns with the new torque converter. He said that it makes the van use too many rpms from a dead stop. (go figure, it's a higher stall compared to the stock unit.:thumb: )

I am flying up to get the van this weekend. I am sooooooooooo excited!!!!


Oh yea, I also got something else in the mail today. I opened the box, and found a nice "used" T4. The shaft spins smooth. No nicks on any of the blades. Absolutely no play in the shaft. My measurements tell me it's a T04B "V" trim compressor in a .60 A/R housing. The turbine is a "P" trim, but it's in a huge 1.32 A/R housing. Guess it's time to look for a smaller turbine housing for my needs. I doubt this would spool before 4500 rpms.

Now I have to decide which vehicle gets the twins and which gets the T4.

Ondonti
05-11-2007, 05:16 AM
id put the more spool fun turbo in the van.
and the balls to the wall in the baron :P

You probably think opposite.

Wink
05-17-2007, 02:57 AM
You're probably right. I will need the early spooling setup for any kind of towing/hauling I may do with the van. With a class III receiver hitch, and load levelers, I'll need all the down low torque I can muster to get an additional 6k lbs to move forward at lower rpms. Plus, it has the automatic transmission. So, I doubt I'll ever get above 5800 rpms anyway.


I wonder how a 1.32 A/R turbine with a "P" trim will spool on a 3.0L?

Probably not until after 4k rpms. Guess I will have to find a .58 or .69 A/R housing for my T4.


Oh yea, I almost forgot.........


.... I think I just fell in love with the van. It drives sooo well!!! And it's super comfortable for the "long hauls" too.

Ondonti
05-17-2007, 04:58 AM
might not spool at all.
Ive got a .63 a/r (t3 4 bolt) P trim
Difference between the .63 and .82 is supposed to be 300 rpms on a honda...looks like you will spool 1000 rpms slower by default and your motor wont move as much air to begin with.
Im guessing you might get 5psi @ 4500rpms
That turbine setup is a 900whp kinda setup. Must be from a diesel to be so lopsided.