PFL Turbo - Tuned By Gibbons

Started by Essex2Visuvesi, September 30, 2016, 00:43

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Essex2Visuvesi

#25
October 21, 2016, 16:48 Last Edit: January 1, 1970, 01:00 by Guest
Quote from: "Alex Knight"For the SW20, but food for thought nonetheless:  m https://twosrus.com/catalog/product_inf ... ucts_id=96 m

Thanks for the link

I'm going to speak to Headcase as Scottie has suggested he sells a deck lid fan "Kit"

Essex2Visuvesi

#26
October 22, 2016, 21:16 Last Edit: January 1, 1970, 01:00 by Guest
This weeks ebay bargain


35.00 delivered  s:) :) s:)

The manifold is on its way back from the Fab guy so hopefully I can start soon  s:) :) s:)

Essex2Visuvesi

#27
October 23, 2016, 17:43 Last Edit: January 1, 1970, 01:00 by Guest
Right

Having a few issues attaching the actuator   s:roll: :roll: s:roll:  
looking at the pics of other PE turbo kits it seems the arm on the wastegate is 90Deg out

Can anyone who has the PE Kit installed take a closeup pic of the turbo? particularly the actuator, rod and wastegate arm

Anonymous

#28
October 23, 2016, 18:06 Last Edit: January 1, 1970, 01:00 by Guest
Take a close pic of your wastegate arm

Essex2Visuvesi

#29
October 23, 2016, 18:49 Last Edit: January 1, 1970, 01:00 by Guest
Quote from: "rbuckingham"Take a close pic of your wastegate arm

If you look at the 6th Pic of the first post you can see the orientation of the arm in the closed position

Anonymous

#30
October 23, 2016, 19:17 Last Edit: January 1, 1970, 01:00 by Guest
Then you will need to get that sorted or get a bracket made with a bespoke actuator and bolt to the exhaust housing. My arm points towards the engine so towards the bottom of your pic.

Essex2Visuvesi

#31
October 23, 2016, 21:17 Last Edit: January 1, 1970, 01:00 by Guest
Thanks for that.... I thought it wasn't right

May have to do some jiggery faffery

Essex2Visuvesi

#32
October 29, 2016, 10:48 Last Edit: January 1, 1970, 01:00 by Guest
After much buggering about I have found the correct bracket and have one on order
JDM Parts were very helpful and are sending me just the bracket as they had a customer return with a faulty actuator for the cost of the postage  s:) :) s:)

I know I could have made one up myself but for time involved it seemed silly


Power Enterprise were not much help as all the email addresses I have found for them bounces back as undelivered

The manifold is back and repaired.  Although I'm having a new tubular one made up to the same specs.

I was going to wrap the manifold but after doing a little research there seems to be 2 trains of thought on this.

This post by Guy Croft makes for interesting reading:-
 m http://www.guy-croft.com/viewtopic.php? ... hilit=wrap m
As some of the older members will probably know this guy is a genuine legend when it comes to the Fiat/Lancia Twin cam engine

Been doing some research into wideband sensors, what are people opinions on this one?

Essex2Visuvesi

#33
October 29, 2016, 16:03 Last Edit: January 1, 1970, 01:00 by Guest
Compression test done today

Cold Engine that hasn't been run for about 3 weeks
150,150,145,143

Was hoping for a little better than that  s:( :( s:(

Also looked at where to fit the ST205 Chargecooler.  Big problem, no room at the inn, even if I relocate the battery

1979scotte

#34
October 30, 2016, 07:32 Last Edit: January 1, 1970, 01:00 by Guest
Innvoate are reccomended by Link or Syvecs something like that so must be ok. Some people had issues with their sensor but they use the latest Bosch these days.
I was going to get there MTX range but now i think i may get the Aem wifi X as it combines AFR with EGT and it doesnt require a gauge. Will display on your phone or tablet over wifi.
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

Anonymous

#35
October 30, 2016, 07:56 Last Edit: January 1, 1970, 01:00 by Guest
No gauge? But what will the other half watch

1979scotte

#36
October 30, 2016, 08:16 Last Edit: January 1, 1970, 01:00 by Guest
Quote from: "rbuckingham"No gauge? But what will the other half watch

The road as i am too busy watching tablets/gauges.

Another reason i like innovate is you can re calibrate the O2 sensor some people think this is a drawback they are wrong.

 m http://www.innovatemotorsports.com/reso ... ibrate.php m
First they came for the socialists, and I did not speak out—because I was not a socialist.
Then they came for the Jews, and I did not speak out—because I was not a Jew.
Then they came for me—and there was no one left to speak for me.

Free Ukraine 🇺🇦

loadswine

#37
October 30, 2016, 08:38 Last Edit: January 1, 1970, 01:00 by Guest
One of the most important things with the PE turbo, is to brace the manifold. With the turbo sitting above the manifold, it is harder to brace, and , as with a lot of these tubular manifolds, be prepared for cracking at some point. That would be a good reason not to wrap it, for me, to keep an eye on things.
No Roadster any more, Golf 7.5 GTi Performance

Essex2Visuvesi

#38
October 30, 2016, 09:22 Last Edit: January 1, 1970, 01:00 by Guest
Quote from: "loadswine"One of the most important things with the PE turbo, is to brace the manifold. With the turbo sitting above the manifold, it is harder to brace, and , as with a lot of these tubular manifolds, be prepared for cracking at some point. That would be a good reason not to wrap it, for me, to keep an eye on things.

As you can see from the previous posts the cracking has already happened and has been repaired. I will be bracing the manifold in some way

loadswine

#39
October 30, 2016, 09:36 Last Edit: January 1, 1970, 01:00 by Guest
Yes, I had seen that, and note that it has been repaired.  It did look a bit distressed.  s;) ;) s;)
My point was, that even with really good welding on the manifold, the design is such that it will be at risk. I have been through this myself. My first turbo was a PE, with a cracked manifold, amongst other things, which I had welded and then completely re installed, but the manifold cracked again, after a short time. I had a small, but effective brace installed, to triangulate the manifold, and it held up for a good long time, after that.
The brace basically ran from the turbo flange, back to the flange that meets the head. Its not the only way of doing it though. Be interested to see what you go for
No Roadster any more, Golf 7.5 GTi Performance

Essex2Visuvesi

#40
October 30, 2016, 13:28 Last Edit: January 1, 1970, 01:00 by Guest
Quote from: "loadswine"Yes, I had seen that, and note that it has been repaired.  It did look a bit distressed.  s;) ;) s;)
My point was, that even with really good welding on the manifold, the design is such that it will be at risk. I have been through this myself. My first turbo was a PE, with a cracked manifold, amongst other things, which I had welded and then completely re installed, but the manifold cracked again, after a short time. I had a small, but effective brace installed, to triangulate the manifold, and it held up for a good long time, after that.
The brace basically ran from the turbo flange, back to the flange that meets the head. Its not the only way of doing it though. Be interested to see what you go for

Don't suppose you have a pic of the brace?

loadswine

#41
October 30, 2016, 13:36 Last Edit: January 1, 1970, 01:00 by Guest
I do somewhere, also my old mate Perry made a barce for his PE too, slightly different design, but it would have been effective. Perry was a bit of a dab hand with this sort of stuff. I might have a pic of that one too. I will have a hunt around and see what I can find.
No Roadster any more, Golf 7.5 GTi Performance

loadswine

#42
October 30, 2016, 14:21 Last Edit: January 1, 1970, 01:00 by Guest
Found them!
First of all, Perry's brace:-





And this was my attempt:-





No Roadster any more, Golf 7.5 GTi Performance

Essex2Visuvesi

#43
October 30, 2016, 16:00 Last Edit: January 1, 1970, 01:00 by Guest
Cheers for the pics, most informative! Perry's brace was pretty much what I had in mind.
Annoyingly we were going to go with the blue engine cover and Brace as you have  s:( :( s:(  so we'll have to think of something else!

loadswine

#44
October 30, 2016, 17:02 Last Edit: January 1, 1970, 01:00 by Guest
First apologies for messing up your last post. Pressed the wrong button, when trying to add a quote.   s:oops: :oops: s:oops:   mod slip by me, I'm afraid, sorry.

I think Perry's was a good, robust solution. Pleased to see you've made a start. No problem with replicating that colour scheme, as that was 5 cars ago for me and that setup no longer exists on that car. Current owner has a 2GR V6 in there.  s;) ;) s;)
No Roadster any more, Golf 7.5 GTi Performance

Essex2Visuvesi

#45
October 30, 2016, 17:35 Last Edit: January 1, 1970, 01:00 by Guest
Quote from: "loadswine"First apologies for messing up your last post. Pressed the wrong button, when trying to add a quote.   s:oops: :oops: s:oops:   mod slip by me, I'm afraid, sorry.

I think Perry's was a good, robust solution. Pleased to see you've made a start. No problem with replicating that colour scheme, as that was 5 cars ago for me and that setup no longer exists on that car. Current owner has a 2GR V6 in there.  s;) ;) s;)

No problem!

Now have the manifold in Hand so on Adam and I started pulling bits off   s:twisted: :twisted: s:twisted:  

Yes I know he's not a real man.... there's an instruction manual!   s:shock: :shock: s:shock:  


Crash bar and exhaust is next on the list for removal. But first a few days of plus gassing
Suprised at the size of the std exhaust, the CHE exhaust thats on the way from the US should be considerably lighter


If anyone wants the stock system (Manifold is sold and I'm keeping the sport cat) then its free to whoever wants to collect it once its off

Essex2Visuvesi

#46
January 19, 2017, 00:47 Last Edit: January 1, 1970, 01:00 by Guest
A little bit of up update
The Acutaor bracket problem has been solved with a bracket from Kinugawa (meant for a subaru legacy) that just needs one of the fixing holes moving
Have decided to go with a water-air intercooling with the pre rad in front of the normal radiator.
The pre rad is from a Ford Focus RS MK1. A mate had upgraded his one for for a front mounted air-air so I grabbed it,  I grabbed the chargecooler but it wouldnt fit.  I also picked up a chargecooler from Toyota Celica T205 but again it wasn't suitable without some convoluted boost piping
Need to find a TRD stage 2 spoiler to give some extra airflow to the pre rad
Water pump and resevoir are both again from the MK1 Focus RS
Trying to find a water intercooler that will fit in the stock PE pipework proved tricky as it doesn't allow much length but finally found one to fit

Not the prettiest in the world but they do the job and will maintain the existing pipe run.  Keeping the boost run as short as possible should reduce boost losses and refuce lag.
The 2ZZ injectors are on their way to injectortune for a clean and flow test.  Knowing the true max flow rate of each injector will make the ECU setup easier.

This brings me to my choice of ECU
I was going to go E Manage Ultimate but after some further research this may not be the best option, so I'm now considering the Apexi PFC (Stupidly I sold the one I bought last year) one of the reasons is that I have made contact with a member of spiderchat who is running almost the same setup as I'm planning.  And has offered me his maps to use as a baseline.  The PFC also has the advantages that it doesn't fight with the existing ECU and it's true plug and play into the existing harness. The car is an import so I wont loose the immobiliser or alarm as it doesn't have them (well not facory ones anyway  s;) ;) s;)  )

Other parts purchased include an wideband AFR sensor and gauge
More gauges than a 747. I now have 7 pods for guages. 3 will be on the top of the centre cubby, 3 on the pillar and the boost gauge on the binnacle.
Gauges:-
[list=]AFR
Boost
Oil Pressure
Oil Temp
dual Intercooler temp in & out
EGT
Chargecooler water temp[/list]

Still need to decide on an electronic boost controller

That's about all for now, hoping to start spannering when the weather improves

Jims

#47
February 21, 2017, 19:22 Last Edit: January 1, 1970, 01:00 by Guest
Going to be following this and hopefully stealing some of your idea's  s:D :D s:D     How bad a fit was the celica intercooler as id considered that idea myself

Essex2Visuvesi

#48
February 21, 2017, 20:49 Last Edit: January 1, 1970, 01:00 by Guest
As far as we could work out there is no where it can be fitted that doesn't either hinder access, create convoluted boost pipe runs, or just look messy.
one to consider might be the Focus RS MK1 chargecooler

Essex2Visuvesi

#49
March 3, 2017, 20:34 Last Edit: January 1, 1970, 01:00 by Guest
Was hoping not to spend any money on the car this month, but these have just appeared on evilbay

Someone please buy them before I do!

Must resist
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