FI Build-up - German Plenum/TB & MS-1

[Vee Dub Nut]

Got my turbo in today.. Thanks Miniman!





Did a little test fitting for everything. Got my list of piping needed to finish up the job. I'll be ordering everything in stainless and welding it up at work.





Fits great! Overall I'm very excited to finish this up. One more cool pic for good measure

[miniman82]

Glad it got there OK.

Do you like the polished compressor? That was my favorite thing about it, took me forever to do by hand though.

[Vee Dub Nut]

Glad it got there OK.

Do you like the polished compressor? That was my favorite thing about it, took me forever to do by hand though.

Yea.. it looks great. Too bad it will be hidden most of the time

[Vee Dub Nut]

Got a little more done at work today..

So my KKK K24 has a slightly different flange than a normal T3 turbo. I knew this going into it, but had read online that with some quick re-drilling of a T3 flange, the K24 will bolt up.

Here you can kind of see the flange on the K24


First I thought it would be a pretty easy modification, until I got the header to work and realized that the number four and three primary tubes were in the way. No matter what we tried, we couldn't get any of the tooling in the mill close enough to the turbo flange without hitting the primarys. Our solution.. cut if off the header for easy access.

Yikes... I'm not a big fan of cutting on a brand new $250 header, but you got to do what you got to do.



With the end cut off, it was real easy to chuck up in the mill and bore new holes for the smaller K24 flange.



I brought the cut off part home to verify if fits the turbo, and it does. So tomorrow we'll be tig'ing it all back up.

My other plans for tomorrow include modifying my oil sender adapter for my turbo feed, doing a slight mod to my turbo feed flange, and modifying my FPR adjusting screw so its boost referenced.

[miniman82]

Are you going to port the turbine inlet of the K24 so it matches the T3 flange 'hole'?

[Vee Dub Nut]

Are you going to port the turbine inlet of the K24 so it matches the T3 flange 'hole'?

No.. the turbine inlet is actually slightly bigger then the T3 flange. The only part where the flange is smaller is across the top and bottom by a little bit.

[Vee Dub Nut]

A little more progress today...

Got the header back in one piece.





Drilled my oil pressure/temperature adapter and tapped if for 1/8NPT so that I can put in the turbo feed here.



Lastly I got my bolt modified for my FPR so that it will be boost referenced. I started out with the original bolt at first, but when trying to drill the hole through the center on the lathe, I broke off the bit in it. So in a pinch, I found another bolt the same size and modified it instead.

Here you can see the heads and the hole that I bored down through it.



Here is the profile view of the bolts. I used the lathe to turn down the end of the bolt, and then put the taper in with the bench grinder. Here you can also see the cross hole that lets the pressure onto the top side of the diaphragm.



Lastly I will solder in a small piece of the 1/8" tubing so that I can attach my line to the plenum



Thats all for tonight. I'll be painting up the header and installing it and the turbo this weekend. I've ordered all my stainless tubing and silicone couplings for the charge pipe, and they should be here on Saturday. Then I just have to wrap up the exhaust, and get oil lines made for my full flow and turbo feed and drain.

Almost there!

[ToRy 70]

While you're cutting and welding up your header, you might consider moving your wastegate flange to the collector. Or are you using an internal WG?

[miniman82]

The turbo doesn't have an internal gate.

[Vee Dub Nut]

While you're cutting and welding up your header, you might consider moving your wastegate flange to the collector. Or are you using an internal WG?

I've done some research, and other than people saying its best to move it, I haven't found any concrete reasons why. My plan is to leave it on the primary for now. I may end up moving it, but I'll cross that bridge later.

[miniman82]

It's not really hard to figure out the why, you just have to think about it for a second. With the gate on a primary and the gate open to control boost pressure, you'll end up with exhuast moving quickly in 2 directions. One direction when that cylinder fires, then reversing as the gas from other cylinders make their way out the gate. In the collector is the best place for it, the gas does not have to reverse direction.

[Vee Dub Nut]

Now that's the best explanation I've heard yet...

[miniman82]

Not that it doesn't work the way it is, I just think it's better to have the gas always going one direction. Mario's setup is one of the best ones I've seen, with regard to turbo placement and WG plumbing.

[ToRy 70]

also, I believe Marty said that you can lean out that one cylinder under wastegate cycling...

if the exhaust gas from the other primaries doesn't reverse, it will at best be "dormant" at the collector... the pressure WILL go down, and thus slow down the turbo because of the loss of pressure on one primary. but it leaves the number 2 cyl with a rapidly fluctuating backpressure which can affect its volumetric efficiency.

think of the wastegate as a controlled exhaust leak, because that's what it is. if you have an exhaust port leak on a normal header, it hisses and lean-pops due to the irregularity in backpressure.

while things will never be equal on an un-equal turbo header, you stand to gain a lot more efficiency and control by letting the wastegate bleed from all four cylinders. I think MinamiKotaro noticed that his boost was a lot more consistent too... less random spiking and creep.

the tough part is getting it to fit so close to the block.here's a pic of how most people do it, this one is made by marty.



did you get the CB wastegate along with the header, or are you getting another brand of external?

[Vee Dub Nut]

I have the CB wastegate too... I did an exchange on some return items for the wastegate instead of getting dinged for the restocking fee.