JoBy

JoBy

The 4" piping to the air filter:

JoBy

The modified header:







We removed the fuel pump cover plate and it can be used as oil return.

jon_volk

ive heard in the past that the hole in the block where the fuel pump mounting boss would drain to is too restrictive to use as an effective turbo drain. Im personally welding fittings into my oil pan.

JoBy

It is better to weld the fitting to the pan, but we don't want to pull the engine just for that.

B4Ctom1

you can do it like procharger and vortech suggest, no leaks and no welds.

83 Crossfire TA

iTrader: (2)

That's where I ran mine, I'll know whether it works soon enough. My thought process is that the pushrod used is greater then the id of the return line that most people use so I'd be surprised if it really ended up being a problem.

JoBy

If you look at the picture you will find two holes. One big hole in an upward slope to the cam and that is for the fuel pump arm. Then there is a smaller (3/8 " ?) drain hole at the bottom with a down slope.

It does not matter if the oil level is above the drain hole as long as the level is not abobe the hole from the turbo drain. Because of the big hole the turbo will still be vented to crankcase pressure.

JoBy

The intercooler is ready.





Air-filter.



And a few more.







More pictures: http://jobyteknik.homeip.net/fredrik/Camaro/2004-02-17/

89JYturbo

Turbos are just cool. I really enjoy seeing how other people fab thier systems- it gives me a lot of ideas. Very nice set-up!

stevedave454

details please

flyboy367

nice job, been thinking about turbos for a while. with the clean job you guys are doing you should start selling prefabbed kits

JoBy

A nice 3" pipe from the turbo to the intercooler.

JoBy

One more pipe done:

JoBy

More pictures of the finished intercooler








http://jobyteknik.homeip.net/fredrik/Camaro/2004-02-27/

JoBy

Some more piping done:



More pictures:

http://jobyteknik.homeip.net/fredrik/Camaro/2004-02-28/

jon_volk

looking good. i like how you made the throttle body elbow.

do you plan on keeping the stock tpi runners on there?

JoBy

Yes, we are keeping the engine stock for now.

sleepybu

where did you get this info

83 Crossfire TA

iTrader: (2)

What part of it? The compressor maps are published, the housings I've got experience with and the power estimates are just simple math…

sleepybu

the turbine houseing sizes like 22cm^2 ...is there away to convert them to a/r

holset's site leves a bit to be dezired

would be nice to see an interchange chart(holeset to holeset) too if they'd let that info lose...

83 Crossfire TA

iTrader: (2)

Not that I've seen. I've seen people publish conversions but there seems to be little connection between them and reality.

I've tried to measure the A/R of a H1E 22cm^2 housing that I had sitting around and got between .97 and .98 A/R trying it in an few different places, but I've got no reason to belive that that would translate to the same number on any other sized 22cm^2 housings (I've seen 22cm^2 housings for turbos from H1C and D sized up to HX60 sized, all of them have different size wheels meaning that if they have the same nossle area they HAVE to have different A/R's.

Really? They've published more actual information then any of the others before garret actually released info on their new line (I truly believe that the reason for this is partially because of how popular some aftermarket and other brands were getting, including Holset).

Holset to holset? I'm not really following there…

sleepybu

i mean like putting a turbine from say an hx35 to a hx40 if that makes sence ...

83 Crossfire TA

iTrader: (2)

Huh… curious…

I always believed that camaros and firebirds are the same under the outer skin, but looking at your pics I'm coming to the conclusion that there are structural differences besides just the obvious external differences (different front sheet metal, different quarters, different sail panels…).

Your most recent pictures of your intercooler got me looking at some of the older pictures. The core support is distinctly different. The IC wouldn't fit like that in a firebird, they have sheet metal walls on the engine side of the radiator opening, on either side of the battery boxes. Basically you'd have to cut out roughly a 2" strip of sheet metal, the length from your battery box to the top of the core support on either side to get even close to putting something like that in there.

I think that the strut towers are different also. I was looking through your pics and the one titled DSC02868.JPG caught my eye. It seems that you either have _a lot_ more room in that section of the engine bay or you've got the turbo positioned much higher then I've tried. On a firebird if you mount the top of the turbo at the same height as the TB in that area you will hit the hood (the hood dips down in that area where the camaro hood is domed the whole way across). Your turbine housing should be a little larger then the turbine housing of the holset that I've been measuring off of and I don't have room to position things like you have them. From your pics it almost looks like if you didn't have your header in the way you could literally drop that turbo down to the frame rail in that area, where I can actually rest my smaller turbo down on the valve cover, leaning over on the strut tower.

Could you measure your v-band flange diameter, and the turbine housing width from the top just like it's sitting in the engine bay, and maybe lay something flat across the fender mounting flange and see how much below that point the turbine is sitting? Maybe measuring from the edge of the valve cover to the closest part of the strut tower would help. I'm really curious to find out if you really have more room there or if something else is going on. From some of the top view pics the inner fender looks like it comes up to more of a point toward the strut tower top plate, where on the firebirds that I've owned it's really a big dome, there is no taper towart the top plate (maybe it's just my imagination).

As a side note, you've got a character in your directory names that is not a valid character in English/windows directory structure (I haven't tried to figure it out but I'm betting it's the hyphen is not a standard, ascii hyphen)… 90% of people won't notice but in my case, limited bandwidth (dialup) and I'm interested in seeing all of your updates, so I've started using some archiving software (basically it goes out caches a copy of your site while I'm not using my machine so I can view it locally at real time later on rather then waiting for it to download) and this has an interesting effect. Since it can't create a duplicate directory name to cache from it creates the closest thing that it can, which the next time around it doesn't recognize that it's already there and downloads it again… If you pay for web hosting bandwidth (or just want to make life easier for a couple of people) you may want to change the directory names on your web site a little…

83 Crossfire TA

iTrader: (2)

yes, it can be done, but I can't imagine where you would get the info you need. There are multiple shaft sizes in the same series and even different main shaft and compressor shaft sizes (it's turned down half way). There's also at least 2 different CHRA designs for each turbo series and the chra casting has to match the ends/housings that you bolt it to. You can also have different housing attachments, v-band/v-band, v-band/flange, flange/v-band (I haven't seen one like this but I bet there's one out there) or flange/flange. It ends up being much more complicated then just swaping X in to Y.

There's a few diesel turbo shops out there that specialize in this, but the couple that I've tried gave me completely wrong information when I was searching for parts, so there isn't one that I trust to actually know what they are doing.

sleepybu

i see

JoBy

FIRST BOOST TODAY

Before:


After:


Note the blue downpipe.

No full throttle yet but it still made good power. We saw about 9 psi boost at 3200 RPM going sideways.

Everything seems to work very well.

denis

Hey let us know how the l98 holds up.....you've given me some inspiration for my upcoming thirdgen to replace the 80.:rockon:


I dunno if I missed it in your posts, but what have you modified/upgraded in the fuel system?

FSTFBDY

iTrader: (33)

Nice...

makes me want to get bussy and start on my HX55 project

JoBy

We have larger injectors that we are going to install.
( 36 lbs/hr )

We also added an extra fuel pump. You see it behind the left headlight in this picture.

JoBy

It is interesting to note that Fredrik bought the Camaro on the 6th of January, less than three month ago. It is his first amarican car, first V8 car. And today was the first time he drove it. ( If you exclude the 10 yards he drove from the flatbed and into the garage the day he bought it. )

83 Crossfire TA

iTrader: (2)

Sweet!

That appears to be a 4" down pipe… is it connected up to the rest of the exhaust? Does it neck down somewhere?

I like how you guys ground all the welds down.

Sounds like it's spooling OK also, so I'm guessing that all the "experts" out there claiming the big housings on those are in the 1.3 A/R range are off (I tried measuring a few of them and got between .97 and .98 every time, I can't seem to figure out how they came up with the big numbers).

Huh… fuel pump, but what else? Is the fuel delivery otherwise stock? Are you adding fuel some other way? (9psi is a bit of boost, should require quite a bit of fuel over stock)

Some other questions from looking at it:
What are the blue pieces that you're using to couple the sections? It almost looks like pieces of a tarp.
Is that a Holset v-band clamp or did you use a standard one? Seems like around here the Holset clamps are hard to come by (the only place that I've found them is from the Cummins Power Systems dealer locally for insane money or from a few bus supply places that are all out of stock), and they have a different lip depth which looks like it should prevent a normal v-band from sealing up correctly.
Does that oil line tie into the front oil galley plug or did you run it all the way down and around to the filter? Is that a custom hose?

JoBy

Yes, it is a 4" that becomes a 3" to clear the frame. It connects to the stock exhaust.



Right now it is only fuel pump and chip. We know that the injectors are too small for higher RPM, but as I said we have 36 36 lbs/hr injectors that we are going to install.

It is cheep waterhose ... like $1 per foot ... If it breaks it breaks ...

It is a SCANIA truck spare part. ( Fredrik is a truck driver and he got a deal on it )
Yes, it is expensive.

Yes it ties into the front oil galley plug. It is a custom hose. First an adapter to the oil gallery and then a custom hose and another adapter at the turbo. It is the hose to the left.

ta84-355

Glad to hear it's working good for you... 9 psi is quite some boost numbers on that stock engine...

I'm having problems getting my Scania Intercooler welded, but mine needs a lot more work than yours did... You haven't got another one like yours laying around?

Where did you get that cheap waterhoose stuff? If it holds up for 9 psi, it sure must be of quite good quality. I can't see myself spending $30-$40 for ONE 90 degree silicone bend..

/Anders

JoBy

Sorry, we don't have any spare intercooler.

We bought the hoses at a local company, Hydraulteknik.

We put the hood back on today.

This shows the hood clearance with the hood fully closed:


And after washing the winter dust off the car.





The temporary industrial pressure meter. ( 0 - 250 kpa )



And finally a short video from a slow roll to 160 kpa ( 60 kpa boost = 9 psi )

JoBy

Some more progress.
http://jobyteknik.homeip.net/fredrik/Camaro/2004-04-11/

The windshield washer tank is back.
A nice "Made For You Products" spark wire loom kit.
A Volvo coolant tank in front of the radiator.
New larger injectors.





And a video ( 5.5Mb ) showing BOV operation.

rtkjadams

iTrader: (2)

Awesome!!!! got a longer video driving while spooling up the turbo. What is the Max boost you are running?


Ray

JoBy

I will try to get some more videos.

We found a weaker spring for the wastegate but it was too weak. Now we only get about 5 psi boost. We never dared finding out what the stock spring was set at but it did not open at 9 psi. That was as high as we dared with the stock injectors.
We are now looking for another spring.

gta324

Nice work Jonas!

Shoud'nt you remove the PCV valve?

/N.

JoBy

Yes we should.
The other side is open air so it does not build pressure.

TurboedTPI

That is a sweet car. Tons of fabrication. I've been through it

JoBy

A short update on the project.

The wastegaste is still set at 5 psi boost.

Fredrik insured the camaro today so now it is leagal to use it on public roads so we took it for a drive.

From low rpm on third gear and keeping the throttle low enogh not to shift down to second ( not much throttle ) it is still at full boost before 2500 rpm. With a manual valve body and WOT it would probably have full boost at 2000 rpm too.

And some expected bad news ... The tranny is now acting funny on second gear, and the tranny oil has a bad smell.

Time to look for a th400.

FSTFBDY

iTrader: (33)

hope to see some new vid's with the new tranny... next I picture a post sayin time for a rear end.


This deff makes me want to get motivated and finish off my project with the HX55 I have

nape

iTrader: (1)

Nice work guys! Definately a cool project that seems to work well. Quite a quick build time too!

FSTFBDY

iTrader: (33)

Bump...... any new news?

JoBy

Not much.

We have a built th400 now but we have not started the tranny swap yet. We are still missing the yoke and we have to build a new tranny mount.

stevedave454

how much are we talking here for that clamp?

JoBy

I found these but I don't know if it is the right angle or size.
http://www.burnsstainless.com/Hardwa...ps/clamps.html

We used a 'spare part' clamp for a SCANIA truck that uses the same turbo. Yes, it was expensive.



Some update.

We finally got the fan housing.

http://jobyteknik.homeip.net/fredrik...12_fan_housing





And the th400 is in place but we are still waiting for the driveshaft.

http://jobyteknik.homeip.net/fredrik...04-05-16_th400

JoBy

We just did the first test with a G-Tech Pro.

The Camaro had a full tank of gas and we were two in the car.
The rear axle is stock with 2.73:1.
The tranny is a th400 with 2.48:1 on first gear. ( The stock th700r4 has 3.06:1 on first gear )

1) 0-60 mph = 4.73 sec, 1/4 mile = 12.87 sec and 118.1 mph
2) 0-60 mph = 4.55 sec, 1/4 mile = 12.73 sec and 118.4 mph
3) 0-60 mph = 4.49 sec, 1/4 mile = 12.70 sec and 117.8 mph

( We still only use 10 psi boost )

nape

iTrader: (1)

How much does the car weigh? I figured around 3900lbs and plugged it into an ET chart. You guys have enough MPH to run mid 11s.

What RPM are you shifting at? Does it bog bad out of the hole with those airplane gears in it?