Diesel Place banner
21 - 40 of 145 Posts
Discussion starter · #21 ·
Discussion starter · #22 ·
After a couple hours of baking, I shut the oven off and let it sit until this morning. I pulled it out before we headed to church this morning. Here are some photos of the result. I think it looks pretty nice, but I guess we'll see how it holds up. The other housing in the last two photos is the original GM-5. Whose idea was it to try something this big?
 

Attachments

Discussion starter · #23 ·
The compressor housing doesn't look nearly as nice as the turbine. Part of the problem was the operator learning to use the air brush. Part of the problem was the operator contaminating the freshly applied coating with debris. I still have no idea where I kept picking up the debris, but it happened more than once. A more thorough cleaning of my work area would have made a huge difference. If you look close in the photos you can see all sorts of crap in the clearcoat. You can also see spots from where larger drops of clear hit the surface. I started spraying this at 40 psi, but then cut back to 30 which seemed to work much better. The duracoat did not require any thinning to spray easily through the air brush. It was much thinner than the turbo-x.
 

Attachments

It will be hard to see the imperfections in the compressor housing when you go rocketing by with the hood closed!
 
  • Like
Reactions: paleyjim
Discussion starter · #25 ·
True.
This whole coating part of the project grew out of just grinding off the emblems and letter/numbers from the housing. I was going to just bolt it on as it was - old used turbo that had been sitting on my shelf for years. I should be happy it looks as good as it does - and I am, actually.
I'm not doing anything with the center section right now, so it isn't going to be very pretty anyway.
I did some poking around on the siliconintakes website last night to get some ideas for intake plumbing, but I didn't get anything ordered yet.
 
Looking good, James!

For the tune, I suspect we'll have some trial and error. There's a balance between keeping enough timing advance to maintain acceptable throttle response, and retarding it to get some heat to that housing! Your current tune will go in the trash except for the trans settings we worked on and will continue to tweak.

Are you going to wrap and/or coat your crossover pipe?

And don't worry too much about feedback from the DB2 crowd on how a turbo like yours will work unless you plan to swap to a DB2.
 
  • Like
Reactions: paleyjim
could be interesting to have a couple before and after dyno runs....
 
Discussion starter · #28 ·
Looking good, James!

Thanks! I'm trying to at least do something on the project every night I've got a few more photos, but not sure I'll get them posted tonight.

For the tune, I suspect we'll have some trial and error. There's a balance between keeping enough timing advance to maintain acceptable throttle response, and retarding it to get some heat to that housing! Your current tune will go in the trash except for the trans settings we worked on and will continue to tweak.

That works for me. Just out of curiosity, I'm planning to run this turbo with my current tune as well as a factory tune to see how it acts. I'll be in contact with you as things get closer.

Are you going to wrap and/or coat your crossover pipe?

Yes. I will be wrapping it. Need to go back and review some Turbonator threads about exhaust insulation. Seems to me they have some ideas I liked. I do have some DEI titanium header wrap that I might use too.

And don't worry too much about feedback from the DB2 crowd on how a turbo like yours will work unless you plan to swap to a DB2.

Yeah the electronic pump can give you flexibility you just can't get with mechanical. We can't get the same amount of fuel, but we do have flexibility.
 
Discussion starter · #29 ·
could be interesting to have a couple before and after dyno runs....
Agreed, but probably not going to happen. My GTECH data has proven to be unreliable, so I may not even bother with that either.


I did some searching a while back and found some dynos that aren't too far away. I think I made a list of possibilities and will have to see if I can find that list. I may make some calls and see what I can set up.


I would probably need custom trans programming to hold it in 3rd and keep the converter locked. Anybody got other suggestions?
 
Discussion starter · #30 ·
Just a couple photos. Not a lot of progress, but I'm getting a little done.
-The turbo is loosely assembled until it can be bolted on and the housings properly clocked.
-The current status of the downpipe fabrication. I took a few measurements seems to indicate that this is going to be a VERY tight fit to the receiver dryer. I may have some rework to do.
-The downpipe flange mated up with the turbo. Fits pretty well.
-Vband clamp installed and snugged up.


I've also pulled the upper intake off and made a tracing of it in case I decide to fabricate a new one. I'm a bit up in the air about that yet. What I would like to build will challenge my fabrication skills.
 

Attachments

Discussion starter · #31 · (Edited)
Well, I just couldn't bring myself to use the turbo without going through the bearing housing. I just ordered a rebuild kit from spturboost.com. I probably should have asked here first for a recommendation, but it is done. I'll post up pictures of the rebuild when it gets here.

I am hoping to work a little on the upper intake tonight, but will have to see what my wife has planned for me.
 
I am hoping to work a little on the upper intake tonight, but will have to see what my wife has planned for me.
Don't ask her.... tell her YOU need her help...LOL

And let us know how that works out for ya... and pics of the knot she gives ya....:clap:
 
Discussion starter · #33 ·
She doesn't leave marks...
 
Discussion starter · #35 ·
I got delayed by a couple things: I noticed a funny tear/crack in the steel I was using to fab the upper intake flange - so had to scrap that piece and start over. My hydroboost leak also started getting bad so that rebuild moved to the top of the list.


But here are some photos of the progress from last night. I pulled the compressor and turbine housings back off and stripped down the center section. This is the first time I've rebuilt a center section and I was amazed that the rebuild kit contained every removable part in the bearing housing. The parts are all lined up in order with the new parts matched up in the bottom row. I hosed the housing down well with brake cleaner and blew some high temp paint on it. It is still wet in the photo and will dry much flatter.
 

Attachments

Discussion starter · #36 ·
I cleaned up the shaft with brake cleaner and a scotch bright pad and got the new sealing ring installed. Then called it a night. I hope to make some more progress on Friday.
 

Attachments

nice kit, comes with the up-graded 360 degree thrust plate, and the gapless ring for the turbine side of the CHRA... before you assemble it, if could please measure the outside diameter of the brass bearing/bushings, and the thickness of the turbine shaft where the bearings ride, and also where the compressor wheel rides on the shaft....
 
also i notice its a 6 sided nut for the compressor wheel, normally this indicates that it needs to be balanced by a machine, and is not component balanced, but dont worry, BW/schwitzer have an excellent track record of unbalanced rebuilds...
 
Discussion starter · #39 ·
nice kit, comes with the up-graded 360 degree thrust plate, and the gapless ring for the turbine side of the CHRA... before you assemble it, if could please measure the outside diameter of the brass bearing/bushings, and the thickness of the turbine shaft where the bearings ride, and also where the compressor wheel rides on the shaft....
Not sure what kind of precision you are looking for. I probably should have just used the caliper. Grabbed these very quickly this morning before heading to work. I'll try to double check them before assembly. Sorry, no metric measuring tools.


Bearing OD: 0.7515"
Shaft Dia at bearings: 0.4567"
Shaft Dia at comp wheel: 0.3149"
 

Attachments

Discussion starter · #40 ·
And a couple shots of the housing after baking last night...
 

Attachments

21 - 40 of 145 Posts
Top