After a lot of Mr. Murphy incidents I'm back on track again.
Passenger side manifold is now finished (except for the wastegate pipe).

I'm also close to finish the installation of MegaSquirt EFI computer, almost the whole ECM harness is finished - I get sensor values etc. into my laptop now so it's close... Just need to finish the injector harness.

The whole project:
http://www.itv.se/~a1003/turbo/

Pictures of passenger side manifold:
http://aldengard.lixom.nu/gallery/exhaust_parts?page=8

Pictures of EFI harness etc.
http://aldengard.lixom.nu/gallery/EFI_computer

I'm about to start to work on the intercooler, some fabricating needs to be done because I'm moving the alternator to where the air-pump was, and I also need to move the PS pump a little.
And also the two downpipes must be fabricated.

Besides that I'm ready to fire it up... So give me a few more weeks.

/Anders

Looking great....

DId you assemble the megasuuirt yourself? the pcboard etc?

Which version is it also. fuel only or fuel and spark? deff keep this thread updated on progress. and how it works out.

I built it myself. It's MS 2.2. for the moment. I bought it when the 2.2 version was available via the first group buy.
it'll only control the injectors - but I'm planning on connecting a 4 pin HEI module later this year. Hopefully someone can make it work with the stock 7 pin HEI I have laying around till then... Would be cool

We'll see how well the intercooler works out, I might install some sort of MS controlled Alcohol/water injection too.

I'll post updates as soon as I get it to work. The snow is almost gone now. Great....

/Anders

I modified the PS pump bracket by deleting the provision for the AC-compressor. It's almost finished, I shall add a small pipe as a header bolt spacer.. That'll make it strong enough..

Pictures:
http://aldengard.lixom.nu/gallery/mi...bo/ps_bracket2
http://aldengard.lixom.nu/gallery/mi...bo/ps_bracket1

This mod is perfect, I can still use the stock PS pump and also keep it in the stock position...

Now I have to make a new bracket for the low mounted alternator. I wonder if I can use some sort of stock bracket from another car that had it mounted low from the factory...Hmmm.

Today I'll start on the downpipes, they'll go from 3" into 2.25" (yuck), but I haven't got the time to make a 3" Y-pipe... I'll reuse the one that came with the Edelbrock headers I had before.

/Anders

Man, I couldn't stand all the extra steel hanging off of mine or the fact that it wrapped around the manifold so I completely hacked mine up:

Well today I finished the downpipes. I only have to weld them to the turboflange (I haven't bought them flanges yet). I just won't make my own, it's too much work...





I've also finished my AC-delete box



And I've cut the intercooler core down so it'll fit. Now I just have to make the new end tanks.


The intercooler core comes from a SAAB Scania truck and is 70 mm thick - that makes it about 20 mm thicker than the old AC-heatexchanger that was there in the first place..

/Anders

heh... seems like you're doing a lot of the same work I did a while back

check out my heater box:

OH man, why did you have to show me that picture. Now I have to redo my VERY ugly looking AC-delte box...

You did a real good job with yours.. :hail:

I guess I'm starting to panic a little. The snow is gone, and everyone else has their cars ready for the season. I haven't got the time to make good looking parts right now..

/Anders

I know what you mean by starting to get anxious... I've been trying to get the Z28tt started for the first time in 2.5 years, with the new engine, wiring harness, etc, and it's been troubleshooting one thing after another. Now I'm just trying to get a good consistent spark :/ Your car is lookin good, though!

Don't worry about the box looking somewhat amorphous. The cool thing about fiberglass is that it's polyester resin, and so is body filler… whip out the bondo and fill all the low spots, sand it smooth and no one will know how rought the thing looked when you started making it. If you haven't noticed I get weird and **** retentive with some stupid stuff which sometimes results in not much besides projects taking much longer then they should. For example, after cut, welded and fitted that PS bracket, I pulled it back off the car, ground the whole thing smooth, painted it…

WRT to getting projects done… well… I was in that mode a little while ago, and somehow got completely sidetracked into finishing building my tig welder (someplace I actually posted that I'm going to set that aside till summer and finish the car…), playing with that, messing with other people's cars… I'll never really have anything done.

The summer came and went away. During the whole summer I had serious starter problems and in august I lost interest in the twin turbo project.

But yesterday evening I installed a new CVR ministarter and the engine fired up directly... :-)

The oil feed and return lines are installed. The new fuelrail too. I'm about to replace the old Audi fuelpump with a new higher pressure Bosch 250 l/h unit. I'm also about to install a WB O2 sensor to supply the MegaSquirt EFI system with a nice WB signal (see own thread about this under DFI forum).

I'm still waiting for the intercooler to be welded but a lot of other things have been fixed during the summer.

I'll keep the pace up now, I hope to have a somewhat finished car at the end of january.

Here's the most recent picture:



/Anders

The car is finally running with MegaSquirt EFI. Next week I'll start to tune the boost part of the fuelmap, so far it's only tuned for NA.

I just need to install the Intercooler and get the silicone hooses from the post office and then I'm ready to go.

The car has found some new power via the fuelinjection instead of the old carb, boost here we come.

Here are some pictures of the current setup.
http://aldengard.lixom.nu/gallery/misc-turbo/IMG_7502
http://aldengard.lixom.nu/gallery/misc-turbo/IMG_7504
http://aldengard.lixom.nu/gallery/misc-turbo/IMG_7503