Yesterday i showed you that tube creation which was built to emulate a dummy engine block, it took a few hours to do but it was essential to keep progressing, getting into it early this morning i warmed up with a decent TIG session and a coffee of course.
I was lucky that the throwout bearing ID was 33.1mm and that was the exact size of some tube i had lying around, you can never have too much scrap metal laying around!
Most of the other steel was from metalland, i love my local metalland and i bet they love me even more, theres a product they sell called ERW Bright, it comes in oval, square and round, it welds really nicely and is dirt cheap.
Its always a gamble to see how much the welding process has “pulled” the steel, the best way to decrease “pulling” is to have as smaller gap as you possibly can between joins, a little extra time in the building process saves a lot of pain when fitting. Also tack as many positions as possible and then start your weld on the opposite side of the tack.
The frame slid in perfectly and bolted up to the engine mounts nicely.
The dummy head can then be lifted on to the top plate.
I used the factory head bolts and cut up some sleeves to eliminate taking 1 hour to tighten them up, head bolts are 11mm and therefore impossible to get nuts for, here is where a massive bolt collection comes in handy, M12 Nyloc bolts will tighten up nicely on the 11mm thread, not ideal but it works.
With the head now bolted down and in place i can fit the turbo and measure up a heap of things.
The first thing i wanted to work out was the waste gate position, i had no room in below the manifold and wanted to make the waste gate easily accessible.
Half an hour later and heap of grinding, hole-sawing, filing and TIGing it was a problem solved.
The waste gate pipe will exit out into the wheel well, ill leave that for another day though as there a stack of other jobs to do.
Next step design an intercooler and get that ticked off!