Based on what I've picked up over the years..
If the filter doesn't make you to "woah that's a big air filter", it's not big enough.

There's interesting research on intake temps and forced induction. Yes colder is more efficient, but more unstable and harder to tune. Whereas the impact of pre-turbo intake temps can be largely covered up by timing changes.
So don't worry too much about a few degrees here and there, but standstill heat soak is a biiaatch

Todays arrivals:
Heat protective covers
IAT sensor things to go into silicon
Additional joiner to go between air intake and pipe (removing need for duct tape)

In terms of progress:
Did up engine mount bolts to spec
Started fabricating brackets to hold all the vacuum tube gubbins







Tomorrow will be finalising mounts to a place where I'm happy then starting to add all the hose clips etc

Then when all those things are good I'll look to put some oil in I guess!

Spent an eternity doing up hose clips...lost count of them. BUT.. I think they are all done..

I do need to air/water tight seal the screw in barbs on the vacuum block next as well as the coolant pieces on the turbo.

Ah just remembered I need hose clips on the oil return...

Then it's a question of either joining the O2 sensor wires together or welding in another bung.. hmm..

I'm a bit of a way off filling with oil I think!

This evening I added more hose clips, used plumbers tape on all screw in features.. it's a right pain to get to the engine side turbo coolant pipe to tighten it up, hopefully it's good enough.



I also added the heat covers to the coolant lines and the vacuum hoses that are exposed to the exhaust.



The next stages will be:

• Running new wires to the oil pressure & temp.
• fitting new crush washer to sump
• putting in new oil filter
• filling with oil
• performing crank test with injectors unplugged and spark plugs out till I get oil coming out of oil feed line

I'm leaning more towards wiring in both O2 sensors to the ecu via a single input (1 O2 sensor with wires splitting out to the relevant sockets) anyone know if this is a viable solution?

Once I have that sorted I can then move onto my Wideband sensor.. more wiring! 

Just an observation.
Your thread is THé one I open first when having my morning coffee at the local venta as I am both in awe and captivated by your ongoing detailed display of dogged determination.
I só hope you can get it to work as you want; the petrol head version of rooting for a soap series favorite.

Quote from: Petrus on April  5, 2024, 09:31Just an observation.
Your thread is THé one I open first when having my morning coffee at the local venta as I am both in awe and captivated by your ongoing detailed display of dogged determination.
I só hope you can get it to work as you want; the petrol head version of rooting for a soap series favorite.

That's kind of you Petrus! Yes I hope I can get it to work too..

Had a morning delivery today with some goodies @macdool  thank you for the additional Nik Naks!
@Gaz2405 @shnazzle is this filter big enough?  For reference that's a 35kg lab..

Fitted the oversized air filter- will need to think of a way to hold it in place still.. I suspect zip ties may feature strongly here..


Started on the wiring for sensors.. then thought better of the ground idea and will go for a common ground by the other ones on the back left wheel area.

That filter doesn't even look big haha.
But it'll do the job

Quote from: shnazzle on April  5, 2024, 21:47That filter doesn't even look big haha.
But it'll do the job

That's all I need!

This afternoon I spent WAY too much time trying to come up with a grounding solution.. total waste of time as I could have just used the stock one and added to it.. oh well.

I've added an extra ground wire as a "spare" which will likely be used for an IAT sensor.. writing that I might need more for Wideband and boost...

Wiring continued. Grounds soldered on for oil pressure and temp.
Had to do this one on my back.



Oil feed for turbo all in as well now






So next will be running wires to the gauges in front- I'll neaten them up later when things are actually running..

Ran the wires to the temp and pressure gauges.  Everything is staying out till it's running. Also put the oil filter on. (Blue towel applied to clean up).







image hosting

Then put a bit of oil into the turbo (more blue towel)- kept adding to it every few minutes, it's not dripping it out of it so I'm assuming the oil drain is working!



Finally I ran the, Wideband, MAP sensor & boost controller wiring through the firewall with the old coat hanger trick.





Tomorrow will be either a crank test to check oil flow for turbo or it'll be more wiring for boost gauge and O2 sensor merging... likely the latter as I think I want as few as possible reasons for things not to work before I start it..

off in a moment so not crossing fingers literally but figuratively yes 

The sum total of just less than an hour.. though to be fair some of it was spent trying to extract an old O2 sensor that just WOULD NOT BUDGE!

That's some well-prepared spaghetti.

(and a great Donne reference!)

Quote from: inigopete on April  8, 2024, 13:29That's some well-prepared spaghetti.

(and a great Donne reference!)

Cheers- I snuck in a few mins at the end of a call and finished off the rest:



I'm now having a bit of a tidy up, partly because it needs it, but also because I took the restrictor off the turbo to add oil and put it down somewhere and now I can't find it! 

Quote from: jvanzyl on April  8, 2024, 14:48I'm now having a bit of a tidy up, partly because it needs it, but also because I took the restrictor off the turbo to add oil and put it down somewhere and now I can't find it! 

Such carelessness!
I've never, ever, done such a thing never, ever!

Quote from: Joesson on April  8, 2024, 15:49Such carelessness!
I've never, ever, done such a thing never, ever!

FOUND IT!!    
It had fallen into the compartment in the subframe by the engine Mount..








Next step is plug in oem ecu, remove spark plugs, unplug injectors, fill with oil, connect battery and do the crank test... anyone know how much oil is "normal" to come out of oil feed?

SUCCESS!



Oil feed works!

No coolant in system yet, tomorrow if I get a chance I'll wire up the boost controller and try to apply a basic map and start it.

Not incredibly sure about putting the Wideband sensor in to start with.. don't want to fry it inadvertently..

Coolant largely there.. and everything wired in (it's a bit of a mess but will neaten it up once I have it working)..

Which leads me to the next bit... I'm running windows Virtual machine in order to communicate with the Emanage.. only there aren't any lights on it and it doesn't show up as "online" within the software...

I'm currently installing windows xp onto an old machine to see if this helps but it would be quite annoying to have the emanage not work after all this time...

But yeah.. at the moment it's good to go.. if it had an ecu!

XP is the way to go.  I have an old laptop just for that purpose.

Rather a momentous occasion today, it turned on!         
It's not idling smoothly and stalled out eventually.. no idea what I'm doing... I'm running @stupink map that he kindly sent me.. just to repeat, I don't actually know what to do next to make it idle better etc.. I know in theory I'm aiming at 14.7? In the AFR.. but yeah..

  i for 1 cant wait to see and here this up and running and good video to show off all this handy work  
please keep going as it cant be to far of now  

Quote from: jvanzyl on April  9, 2024, 23:28Rather a momentous occasion today, it turned on!         

Quite!!!
That must be só satisfying and a proud moment.
´It´s ALÍVE!!!!´
Hopefully an experienced member here can help you out with the set up.

Good work   it always a good feeling even with some teething troubles, I would install a blank/zeroed out map on the emanange for inital startup and idle so you know thats not causing any issues, you only need a map for when you start making boost/driving etc

Quote from: thetyrant on April 10, 2024, 15:34Good work   it always a good feeling even with some teething troubles, I would install a blank/zeroed out map on the emanange for inital startup and idle so you know thats not causing any issues, you only need a map for when you start making boost/driving etc

^^^
What we talked about J