95 mk3 vr6 -> turbo diesel

[zukgod1]

Aw there ya go, it has a T3 foot on it. Makes sense now.

Did you make that plate?
Can I pay ya to make me one? Seriously..

I did not make the plate, but I was planning on making a few templates of it. It would be fairly easy to make up I'd imagine, I've got the majority of the tools needed. I could trace it out on some cardstock and send you a template if you want.

At the manifold I'm running about 27 psi on the top end with my 26/24 but usually it tops out around 22psi.
Before the intercooler and when running the k24 under hard accell I could touch 40 psi (shock).
At that point is when I decided I had better get a FMIC as I was pushing the turbo WAY past it's efficiency range. Then afterword's I could just touch 30 on a good day so I upgraded the FMIC to a larger core and toasted the turbo shortly there after
I know it was due to my driving style so after the first turbo I turned the pump way down and drove nicer and yet the second turbo snapped as well. I didn't know the condition of the second turbo (do now) so I had to just drive nicer. It snapped on level ground with the cruise control set @ 72 mph.
Now I have a hybrid 26/24, the 26 has the same dia shaft so I'm driving it nicer again. I'm going to change over to a T3 (thats why I need that adapter) to gain the larger shaft and also for parts availability. It's hard to get anything other than a rebuild kit for the k series turbos.

That sounds like quite a bit of boost to be pushing for sure, I've got a large FMIC (I'll see if I can dig up some pics of it) but I haven't decided to use it or not. Perhaps I should re-think that if you are having issues snapping turbo shafts.

I do need to figure out what type of Downpipe/IC pipe setup I'm going to use, Once I finish working on the engine I'll start working on that.

-Todd

I think I'm one of the few that have snaped a shaft so dont let that scare ya to much. That and as I mentioned the first one was due to my driving style I'm almost positive. Shifting while under high boost isnt good but it sure sounded cool!!

I would love a tempate of the plate, with measurements would rock.
I'll PM ya my address

Making a DP is fairly easy if you have a mig. make a flange or buy one and a couple of "U" bends and your off to the races.

[fuslit]

I think I'm one of the few that have snaped a shaft so dont let that scare ya to much. That and as I mentioned the first one was due to my driving style I'm almost positive. Shifting while under high boost isnt good but it sure sounded cool!!

I would love a tempate of the plate, with measurements would rock.
I'll PM ya my address

Making a DP is fairly easy if you have a mig. make a flange or buy one and a couple of "U" bends and your off to the races.

I could send you something in the mail no problem.  

I've got a mig and a bottle for it so I should be able to turn out a fairly decent downpipe.

I'm debating about taking my car's current transmission which has a 3.3 R&P but I'd rather do the full swap where I pull one engine/trans and put the next in place.

Either way there are going to be some issues I think. but I was hoping to keep the down time minimized.

Any suggestions where I can pickup the metal head gasket, pump seals (bio-diesel resistant) and downpipe parts?

-Todd

[zukgod1]

Contact myke_w on the board for the head gasket.
I'll PM you his email addy.

As far as the DP is concerned I made the flange out of 3/8 plate.
I wish I would have used 1/2 but I've not had any problems so far and almost 10k miles so must be ok.
Summit racing sells U bends for a fair price or if you weren't to picky you could have a muffler shop bend you some 3" in varying bends like I did and just chop saw where needed to get the shape you need and weld together.

[fuslit]

Andrew, thanks for weighing in on my thread I'm going to use that turbo... it's just my projects move slow and sometimes change direction *grin*

Yeah, that'd be a good design change, tapping the adapter plate would make it a bit easier...

zukgod1: I'll try and get you a template sent out by sat (with all measurements)

-Todd

[zukgod1]

zukgod1: I'll try and get you a template sent out by sat (with all measurements)
-Todd

Thanks Todd that would be great!!!

[fuslit]

Gonna try and paint the block this weekend

-Todd

[fuslit]

so, it's been awhile ... I kinda got side tracked with a million other projects. Also, my cousin and I have been collecting large chunks of iron (milling machines, Lathe, and machinist tools)

while it's hard to tell, I got the block painted and started putting bits back on, then I came to another road block which head gasket to get?


I'm planning on running a metal 1.9 td headgasket but wasn't sure if the piston protrusion was correct for the previous head gasket.

So since I have the milling machine, I used it as the excuse to make a piston protrusion tool to figure out how high the pistons protrude.





The good news is, it works which I'm excited about, now I can continue to work towards finishing the build.

-T

[zukgod1]

The good news is, it works which I'm excited about, now I can continue to work towards finishing the build.

-T

Too cool!

[fuslit]

I drilled steam holes in the head and block for the extra holes that the new 1.9 aaz gasket has. Raceware headstuds in, headgasket is on and torqued down.





You can see here the one spot to the upper right that the gasket doesn't seal, so I found a thread that addressed that and used some high temp copper gasket seal and a piece of innertube to fill in the gap. Again something which is supposed to work well, we'll see I suppose hopefully it won't leak.



Now, I need to pickup some stuff that will allow me to clean up my ip and some other bits that I want to clean and paint before putting on the engine.

-T

[zukgod1]

You can see here the one spot to the upper right that the gasket doesn't seal, so I found a thread that addressed that and used some high temp copper gasket seal and a piece of innertube to fill in the gap. Again something which is supposed to work well, we'll see I suppose hopefully it won't leak.

I sure hope that was a super thick peice of inner tube?

[arb]

Did your valves come in contact with the pistions ?

[53 willys]

Did your valves come in contact with the pistions ?

read page 2....

[arb]

I see it now. :-)  I guess my attention span is not 5 months ;-)  Good to see it was cosmetic.

[jtanguay]

it still looks like the pistons hit the valves with some good force... unless there is a thick layer of soot on the pistons  :lol:

[dillenger1]

looks like he was turning it over without a head gasket in.