Altezza Build!
Altezza Build!
![[Image: IMAG0352_zpscb42e63c.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0352_zpscb42e63c.jpg.html)
Spent the rest of the night beating what I could flat and then grinding it on the big wheel which isn't actually that flat but got me close. Then it was onto the surface table with a ton of engineering blue and some sandpaper taped to the table. Took about 5 hours of hand sanding and some careful localized griding when the blue showed up massive high spots and eventually it got to this.
![[Image: IMAG0354_zps54952eed.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0354_zps54952eed.jpg.html)
Sorted out the wastegate, machining down the flange
![[Image: IMAG0347_zpseb97e226.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0347_zpseb97e226.jpg.html)
![[Image: IMAG0346_zps838f8a27.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0346_zps838f8a27.jpg.html)
Wastegate port cut into shape for the manifold
![[Image: IMAG0355_zps9ae0b521.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0355_zps9ae0b521.jpg.html)
![[Image: IMAG0360_zps30002240.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0360_zps30002240.jpg.html)
![[Image: IMAG0356_zps94c840e7.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0356_zps94c840e7.jpg.html)
![[Image: IMAG0362_zpsf388321f.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0362_zpsf388321f.jpg.html)
Manifold is now fully finished and should never have to come off again hopefully!
Next it was onto the wastegate pipe. I debated with running a screamer but i thought it's just going to be anooyingly loud and get on my nerves so dumped it back into downpipe. Made a pattern to cut round as ali is much easier to fettle than stainless.
![[Image: IMAG0366_zpsaec94ffb.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0366_zpsaec94ffb.jpg.html)
Cut it all in and mounted it up.
![[Image: IMAG0367_zpse51901bb.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0367_zpse51901bb.jpg.html)
Works pretty good. I took the top of the wastegate off and it was opening quite well as I revved and that's without the backpressure of the turbo forcing gas down the wastegate so pretty pleased.
The walbro pump I had died very very quickly so I threw in the bin with anger and found me a nice bosch 044. Apparently brand new, don't want to test it out of the tank as they don't like to pump air apparently so will just have to hope it's all good after it's in and wired up.
Made a new fuel pump assembly to hold it all. Just needs a feed and return hose fitting and then it can go into the tank and wired up using the oem pump positive as a trigger wire for the relay so I can draw straight from the battery.
![[Image: IMAG0372_zpsec815071.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0372_zpsec815071.jpg.html)
I start my new job in a week so I (probably) won't get the chance to make stuff anymore. Definitely no where near as much as I do now anyway so I have a week to fit the pump and get it running sweet, Make a new fusebox as the wastegate will melt it in t he standard position, do all the intercooler piping and the inlet piping into the turbo but I think I'll leave that until later when I decide what air filter to run.
Hoping with the new job and the paid overtime (finally!) to have the car fully turbod and mapped by mid spring/summer ready for the show season so I can make some meets and be able to keep up with my friends
Took the manifold off to do the wastegate pipe and found this. Kept getting errors at high revs saying fuel trim too lean, Haven't tested if the issue is gone yet but I think it was the majorly blowing manifold. It was blowing at every join up to the lambda too so sorted all that. used the wrong size v-band! turns out there are a few tiny differences with them.
Spent the rest of the night beating what I could flat and then grinding it on the big wheel which isn't actually that flat but got me close. Then it was onto the surface table with a ton of engineering blue and some sandpaper taped to the table. Took about 5 hours of hand sanding and some careful localized griding when the blue showed up massive high spots and eventually it got to this.
Sorted out the wastegate, machining down the flange
Wastegate port cut into shape for the manifold
Manifold is now fully finished and should never have to come off again hopefully!
Next it was onto the wastegate pipe. I debated with running a screamer but i thought it's just going to be anooyingly loud and get on my nerves so dumped it back into downpipe. Made a pattern to cut round as ali is much easier to fettle than stainless.
Cut it all in and mounted it up.
Works pretty good. I took the top of the wastegate off and it was opening quite well as I revved and that's without the backpressure of the turbo forcing gas down the wastegate so pretty pleased.
The walbro pump I had died very very quickly so I threw in the bin with anger and found me a nice bosch 044. Apparently brand new, don't want to test it out of the tank as they don't like to pump air apparently so will just have to hope it's all good after it's in and wired up.
Made a new fuel pump assembly to hold it all. Just needs a feed and return hose fitting and then it can go into the tank and wired up using the oem pump positive as a trigger wire for the relay so I can draw straight from the battery.
I start my new job in a week so I (probably) won't get the chance to make stuff anymore. Definitely no where near as much as I do now anyway so I have a week to fit the pump and get it running sweet, Make a new fusebox as the wastegate will melt it in t he standard position, do all the intercooler piping and the inlet piping into the turbo but I think I'll leave that until later when I decide what air filter to run.
Hoping with the new job and the paid overtime (finally!) to have the car fully turbod and mapped by mid spring/summer ready for the show season so I can make some meets and be able to keep up with my friends
![[Image: LexuS-Copy.jpg]](http://i65.photobucket.com/albums/h204/Sparkystav/LexuS-Copy.jpg)
Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.
Sparkystav
14-12-2021, 12:39 PM #123So good work there mate, would love to have access to them sort of tools!
Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.
Sent from my iPhone using Tapatalk
is200turbo
14-12-2021, 02:20 PM #124Great work mate wish I had the tools and skills to do it
Sent from my iPhone using Tapatalk
Made a fitting to go on the back of the rail with a hose coming off it so I can screw the guage on whenever I need to check fuel pressure if it needs adjusting
![[Image: IMAG0380_zpsd28d1255.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0380_zpsd28d1255.jpg.html)
Fuel pump in and fully wired up
![[Image: IMAG0381_zps6871558a.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0381_zps6871558a.jpg.html)
Fused the battery and pump all wired in. Ghetto flying fuse all up in there
![[Image: IMAG0385_zps8463779d.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0385_zps8463779d.jpg.html)
pump all wired up and tidied away so it's nice and neat
![[Image: IMAG0384_zpsef9efbdf.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0384_zpsef9efbdf.jpg.html)
Fitted a filter on the line too, didn't have a sock for the pump.
Power delivery is messed up though. Usually pulls ok and sometimes starts to feel like it's missing until I change gear and power drops right off at about 6k. Sometimes although very rarely it will get it just right and pull like it's trying to escape from the scrap man it's crazy powerful. Only started since I fitted a new pedal position sensor which is odd as the throttle is now a standard set up and I set the tps voltages right, clean maf, everything. Gonna check the plugs and coils see if maybe they are playing up which would suck so bad at that price.
Finally got round to finishing off some bits.
Made a fitting to go on the back of the rail with a hose coming off it so I can screw the guage on whenever I need to check fuel pressure if it needs adjusting
Fuel pump in and fully wired up
Fused the battery and pump all wired in. Ghetto flying fuse all up in there
pump all wired up and tidied away so it's nice and neat
Fitted a filter on the line too, didn't have a sock for the pump.
Power delivery is messed up though. Usually pulls ok and sometimes starts to feel like it's missing until I change gear and power drops right off at about 6k. Sometimes although very rarely it will get it just right and pull like it's trying to escape from the scrap man it's crazy powerful. Only started since I fitted a new pedal position sensor which is odd as the throttle is now a standard set up and I set the tps voltages right, clean maf, everything. Gonna check the plugs and coils see if maybe they are playing up which would suck so bad at that price.
Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.
Sparkystav
14-01-2022, 08:36 AM #127I like the fuel pump top, you make that? Anymore pics?
Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.
![[Image: Supra-logo-toyota-supras-119417_1569_512...duxjro.jpg]](http://smg.photobucket.com/user/rob-savage/media/Supra/Supra-logo-toyota-supras-119417_1569_512_zpslqduxjro.jpg.html){kind=logo}
FOSSIL FUELS
14-01-2022, 09:53 AM #128Lovely but of engineering going in to this.
![[Image: IMAG0412_zpsqzxxcqzl.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0412_zpsqzxxcqzl.jpg.html)
Took the manifold off to try push 2 of the primaries apart as they were touching. Bit of strategic placing of welds and a big ass wedge I managed to get it to settle at this distance. Still pretty dam close!
![[Image: IMAG0418_zpswvihu8ki.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0418_zpswvihu8ki.jpg.html)
Stripped all the insulation off the turbo as it was starting to break and the powder was coming out.
![[Image: IMAG0419_zpsodn00q6z.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0419_zpsodn00q6z.jpg.html)
Re did the insulation, this is the stuff that actually keeps the heat in. Need to cut and weld the stainless on top to seal it in.
![[Image: IMAG0430_zps2krit9li.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0430_zps2krit9li.jpg.html)
Need the dummy turbo fully built to fit a brace, even though the turbo is empty it still needs a brace as the manifold will droop drastically without one. Bung I machined to go in the end of the compressor.
![[Image: IMAG0421_zpstgz9hxnv.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0421_zpstgz9hxnv.jpg.html)
Fitted!
![[Image: IMAG0422_zpstxun5hbb.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0422_zpstxun5hbb.jpg.html)
Now the worst thing about this...
![[Image: IMAG0417_zpsl9ctbahd.jpg]](http://s1295.photobucket.com/user/toshamov/media/IMAG0417_zpsl9ctbahd.jpg.html)
Yup, that's one big ass crack! No wonder it was reading lean. Welded it up, refitted it using firegum and was fine.
Week later (today) I go to mount the brace and notice some white paste on primary 1. After close inspection it has a hairline crack in the same place and there is white stuff under it, looks like it cracked on the bottom too somehow. Just aswel I used firegum! I would not have found the leaks otherwise. So it's coming off AGAIN tomorrow and I am going to reinforce the **** out of it. Had a chat with an exhaust engineer at work and he said it's quite common for that to happen. I'll see what he says about strengthening it so that I can finally put it on and leave it on. If not I will just give up and make a heavy duty indestructible one. Very much a love hate thing with this project
So I think I may quit :x :x :x :x
Took the manifold off to try push 2 of the primaries apart as they were touching. Bit of strategic placing of welds and a big ass wedge I managed to get it to settle at this distance. Still pretty dam close!
Stripped all the insulation off the turbo as it was starting to break and the powder was coming out.
Re did the insulation, this is the stuff that actually keeps the heat in. Need to cut and weld the stainless on top to seal it in.
Need the dummy turbo fully built to fit a brace, even though the turbo is empty it still needs a brace as the manifold will droop drastically without one. Bung I machined to go in the end of the compressor.
Fitted!
Now the worst thing about this...
Yup, that's one big ass crack! No wonder it was reading lean. Welded it up, refitted it using firegum and was fine.
Week later (today) I go to mount the brace and notice some white paste on primary 1. After close inspection it has a hairline crack in the same place and there is white stuff under it, looks like it cracked on the bottom too somehow. Just aswel I used firegum! I would not have found the leaks otherwise. So it's coming off AGAIN tomorrow and I am going to reinforce the **** out of it. Had a chat with an exhaust engineer at work and he said it's quite common for that to happen. I'll see what he says about strengthening it so that I can finally put it on and leave it on. If not I will just give up and make a heavy duty indestructible one. Very much a love hate thing with this project
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