I milled the cut end of the manifold 15 degrees to help tuck the turbo in closer to the motor.
The 15 degree angle will also mean I won't have to re-arrange the wastegate actuator which might otherwise interfere with the intake.

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

What are you going to do with the sawed off part with the heat control valve?

_________________
KAKAWWWWWWWWWWWWWWW!!!!

Toss it. Is there some use for it???

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

Yep, I could use it to rebuild my manifold's valve.

_________________
KAKAWWWWWWWWWWWWWWW!!!!

It's yours. Just pay the shipping. PM me

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

I 'cold welded' the T3 turbo flange to the manifold and smoothed out as much of the transition as I could get to.
I'm pretty jazzed about how well the stock manifold lends itself to taking advantage of the twin scroll design of the turbo.


The 'cold weld' process for cast iron is new to me but seemed like a good way to approach this particular mod.
Time will tell how well it holds up.

Here it is assembled. The turbo is tucked in pretty well.

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

What's cold welding of cast iron?

_________________
Ed
64 Valiant 225 / 904 / 42:1 manual steering / 9" drum brakes

I think this is what he means.

http://www.youtube.com/watch?v=Yopcz-IYDyQ


Greg

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http://www.youtube.com/hyperpack

Yep. That video is a good example.
In a nutshell: Make 1/2" to 3/4" welds.
Peen each weld thoroughly with an air hammer immediately after laying it down.
Let the piece cool completely between making each weld.

The idea is to avoid the large swings in temperature that can cause cracking.

Peening counteracts the stresses of shrinking as the weld cools by spreading the bead out a little bit.

You are also trying to minimize the amount of carbon that migrates up out of the cast iron into the weld bead.

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

It was a waste of time trying to find Holley jets locally. I could find 2 packs on the web but ordering a bunch of separate 2 packs seemed too wasteful of my precious build dollars. Especially since any jetting I do with the 1920 will only be temporary.

My solution was to make an adapter to run 'large round' Mikuni jets.
I have a full selection of these on hand so future tuning will be simple.

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

Ok, a little more progress this past weekend.

Most of the initial block prep is done.
Here I'm tapping the lifter drainback holes for some standoffs.



The standoffs keep a reservoir of oil around the tops of the lifters.

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

I also got started fabricating the new intake manifold.
First I ran a stock aluminum manifold through the bandsaw.



Then cut out some aluminum plate to join the runners and serve as one side of the plenum.



A little fitup work



And some welding


And there's a beginning of the manifold

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

Seems we have almost the same thing going on. Only I don't have all the goodies like a mill, and boy could I use one. I'm going carb first so I'll stay tuned in w your progress.

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225, Offenhauser, Holley 350, A833OD, 3:55, GM HEI,99 Durango starter
BOOSTED! WH1C, BIG FMIC, 10#
Operation Noble Eagle 03-05
Operation Iraqi Freedom 05-07
Operation Enduring Freedom 12- 13

It took forever to find the right extended nose injectors with enough flow.
These are 800cc Bosch injectors used in some Audis and other euro cars.


I machined up some injector bungs to fit them.


And bored my 'manifold in progress' to position the injectors at 30 degrees.




Here's the partially completed manifold with the bungs dropped in.
I'll epoxy them in place rather than try to weld them.

_________________
--> Check out my FI Turbo build <--
--> And the race truck build project <--
--> The Diesel Corvette <--

If you would sir, measure the extended tip portion of those injectors? Im trying to find some that have enough meat to be threaded for 1/8" npt. Or ones that are larger than 1/8" npt.

_________________
225, Offenhauser, Holley 350, A833OD, 3:55, GM HEI,99 Durango starter
BOOSTED! WH1C, BIG FMIC, 10#
Operation Noble Eagle 03-05
Operation Iraqi Freedom 05-07
Operation Enduring Freedom 12- 13