Rob Turbo 3 Posted June 13, 2006 Well over the last month or so I've been doing a bit more work on the 16v turbo project after I left it alone for a while, at the minute I'm focusing (sp?) on the inlet manifold, I've been changing my mind about this for ages but finally settled on this- 1.9 Mi16 manifold flange and fuel rail (chopped an Mi manifold to bits!) Sierra cosworth plenum and throttle body New mounting plate for plenum welded to Mi flange with extra pipe in between I'll show pics of exactly what I'm doing once its finished if you dont fully understand, but for now I'll stick some pics up of a few bits and bobs! I found an excelent place to get ally pipe from but I'm just waiting for them to give me some with a thicker wall, the stuff I've got has a 2mm wall and I'd rather have double that, but the internal diameter matches the Mi runners perfect! Anyway, heres some pics! After the inlet is finished I'm going to move onto the exhaust manifold, not sure if I want the pipes coming over the rocker cover and down into the turbo or along the side of the head and up into the turbo, I've seen both done and could probably go either way, what do you reakon would be best? Thanks Rob Share this post Link to post Share on other sites
Sam 4 Posted June 13, 2006 (edited) Are you not adopting the air horns that are in the GTI6 inlet and Cossie inlets? Why not use a shortened GTI6 inlet? Are you going forged rods and pistons? I'm building a 2.1 16v Turbo at the moment and not sure what to do about rods and pistons. Got a steel crank lined up. Edited June 13, 2006 by Sam Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 13, 2006 I'm going to cut the trumpets off the cossie inlet and weld them onto the plate once the pipes are welded in, one of the ideas I had was to just cut the flange off the cossie inlet and weld it to the Mi flange but the pipes would have been at an angle so thought this would be best Im going for the cossie setup because the throttle body points towards the drivers side so it will make the inlet piping a lot shorter (using the cossie 4x4 intercooler) I'm sticking with standard pistons and rods for now, its an 8v turbo bottom end with 2.0 mi16 head Share this post Link to post Share on other sites
Sam 4 Posted June 13, 2006 Ahh good idea. What power are you aiming for? I'm using an RS500 intercooler with the aim of 400bhp in the future. Can't wait to get it built up, its going to be double my current power Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 13, 2006 Anything over 200bhp would be great! Shouldn't have too much trouble getting that, not sure what the subaru td04l turbo is good for tho! Share this post Link to post Share on other sites
Sam 4 Posted June 13, 2006 I'm pretty sure a guy from work mentioned the TD04 being good for 300bhp but you never know. Exhaust is my main problem at the moment, need to build one with 3" bore Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 13, 2006 I've got 3 metres of 3" stainless pipe to build my exhaust with, dont have the bends yet but can get them easily enough, I'm not worried about the exhaust yet, I want it running before I start that! Havent got the pipework for the exhaust manifold yet, or the flanges! (I have a stainless steel 1.9 mi16 exhaust flange but the bolt holes are in the wrong place so its more or less useless, I do have an s16 exhaust manifold tho, dont think its a good idea to try to weld pipes to a cast flange tho!) Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 15, 2006 Couple more photos, I'm going to stick with the 2mm wall pipe, it will be strong enough etc. So far I've cut the pipes longer than I need and held them in place with plastic pipe and tape, then at the weekend I'm dropping them off at my mates so he can weld them at work next week and get them back to me to mark and cut the plate Once I get it where I want it I'll take it back to him to weld the pipes to the plate and weld the trumpets in place, then its just a case of drilling and tapping the plate to take the plenum, then I can start saving for the exhaust manifold bits! Share this post Link to post Share on other sites
nick 3 Posted June 15, 2006 Looking good mate. Your better off welding the manifold, I reckon the tape will melt on high boost.... Nick Share this post Link to post Share on other sites
Greenys_meanies 0 Posted June 15, 2006 Have you any more photos of the intercooler and mounting, cos i'm fitting one of those to my DT and i'm struggling with ideas on where to route the pipes and how to mount the cooler with the rad lowered.... Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 16, 2006 At the minute its just sat on top of the rad, not a great pic tho: Share this post Link to post Share on other sites
Greenys_meanies 0 Posted June 16, 2006 Thanks Rob. thats about as far as mine got before i put it back together again so i could go to work!! are you mounting the i/c to the slam panel? how are you securing the rad in? i/c tubes over the top i suppose? Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 16, 2006 I'll be making brackets to mount the IC to the slam panel, the rad is sitting in 2 holes in some box section at the bottom and I'm thinking about using cable ties to hold it in place at the top onto some brackets Share this post Link to post Share on other sites
TEKNOPUG 3 Posted June 16, 2006 Hmmm...still can't decide whether to mount mine above or below the rad. Above would be the most obvious but below would be much better for routing the boost pipes. Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 16, 2006 But below would also have longer boost pipes In my setup I'll be using a small angle from the turbo to the intercooler, then a 90 deg. bend from intercooler to TB Very short! Share this post Link to post Share on other sites
sonofsam 5 Posted June 16, 2006 Starting to look cool Rob, great project , look forward to more progress reports and pics. Exscuse my ignorance, but is there a thread by you detailing the 16v head on the xu10 block, sorry i must have missed it if there was,quite intersted to find out diffuculty level. What mangement are you going for? Good luck with future work,o and a very random tip for you, when you come to cut up your 3" pipe a roll of masking tape fits over it perfectly and helps keep cutting line straight if using a hack-saw. Share this post Link to post Share on other sites
Rob Turbo 3 Posted June 16, 2006 I did post a bit about the s16 head on the 8v turbo block, basically, it fits straight on, so far I've had no piston/valve contact with a standard head gasket, obviously you need an xu10j4 bottom pulley etc to fit the 16v belt, all tensioner holes are there and tapped, just need an s16 tensioner I'll be using megasquirt n spark - extra, I've had it for ages now and built it up, havent sorted the wiring or anything yet tho Good tip about the 3" pipe tho! Share this post Link to post Share on other sites
TEKNOPUG 3 Posted June 17, 2006 But below would also have longer boost pipes In my setup I'll be using a small angle from the turbo to the intercooler, then a 90 deg. bend from intercooler to TB Very short! It already does run below on a TT as the turbo outlet points directly down. Share this post Link to post Share on other sites
Alex G 0 Posted June 17, 2006 looks good Rob! for the money i may try and find a 2.0 block rather than £400-500 for low comp pistons if youre sure its a straight bolt on! keep us posted on your progress Share this post Link to post Share on other sites
