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Sloooow twincharge project by truckinwagen on 05 Feb, 2009 17:51
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my rabbit took a dump, slipped its timing and bent a valve one hour after a full professional head rebuild, so unwilling to spend another $250 on head work I decided to rebuild the head myself, and twincharge it while I have it apart.
its a mech head on a hydro block, its getting an ABA camshaft with an adjustable gasser cam gear modified with the diesel outside, ported, but not too much(I didn't feel like putting lots of energy into the head as it is crap anyway)
I did a raintray delete for some added space in the engine compartment as well as removing the brake booster and putting in a buggy master cylinder.
I installed rear discs from a 'rocco as well
I hope to have the head rebuilt this weekend, I have all the valves ready to be lapped and I peened the precups to hold them in
my plans for the motor right now are simply to get it running again, I have the ABA camshaft to get in and working as well as a Cummins injection pump to modify the pulley on, currently the pulley I have has the wrong offset, but I have a friend with a lathe that I hope will help me out with getting all of the pulleys figured out.
eventually I will have a K24(on the motor right now) feeding a G60 supercharger(bought but not here yet and in need of a rebuild) with a large intercooler in between to protect the supercharger from the heat that the turbo will be generating at 25+PSI as well as water/meth into the intake manifold to help control EGT's
I will be flipping the turbo over and running a modified gasser manifold to help equalize the pressure across the cylinders.
the project is moving slowly right now as the car is in a friends shop and I can only really work on it on the weekends for a few hours at a time, but with any luck I will have it fired back up in a month or so. -
#1 by RabbitJockey on 05 Feb, 2009 19:48
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why do people peen the precup in since it can't fall out unless its broken?
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#2 by truckinwagen on 05 Feb, 2009 20:02
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it can fall a little, crushing the HG underneath it causing it to come in contact with the piston, no good.
I peened it just in case since it only takes a minute and cant hurt anything -
#3 by jtanguay on 05 Feb, 2009 20:59
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i would get that head planed... but since its crap don't bother.
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#4 by blackdogvan on 06 Feb, 2009 01:36
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Well i'll be the first to say COOL! this will be a fun build to watch, keep the pics coming!
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#5 by dillenger1 on 06 Feb, 2009 03:11
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what are you thinking of doing for the supercharger when the turbo overcomes it?G60 intakes have that extra port on the throttle body to divert pressure,maybe use that somehow
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#6 by Gearhead on 06 Feb, 2009 05:29
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Isn't a Supercharger just going to be a differential device? It would probably work similar to compound turbos with no need for a bypass, wouldn't it?
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#7 by zukgod1 on 06 Feb, 2009 06:24
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Your planning on filing down the pee'ns where the gasket surface is right?
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#8 by truckinwagen on 06 Feb, 2009 13:35
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I am going to take a sanding block to the head to flatten out the peen marks and the other crap on the surface, I will be careful to end up with a good flat head, and yes I would pay for resurfacing, but the head is ***, so I will save my money for a new one sometime.
because the G60 is a positive displacement supercharger it will compress the compressed air from the turbo further similar to a compound turbo setup, generating higher boost pressures than either the turbo or supercharger could without taking them outside their efficiency ranges.
I will keep updating as things happen.
-Owen -
#9 by Smokey Eddy on 06 Feb, 2009 16:03
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Quote from: "truckinwagen"
I am going to take a sanding block to the head to flatten out the peen marks and the other crap on the surface, I will be careful to end up with a good flat head, and yes I would pay for resurfacing, but the head is ***, so I will save my money for a new one sometime.
because the G60 is a positive displacement supercharger it will compress the compressed air from the turbo further similar to a compound turbo setup, generating higher boost pressures than either the turbo or supercharger could without taking them outside their efficiency ranges.
I will keep updating as things happen.
-Owen
That's really cool. I didn't know that. -
#10 by jackbombay on 06 Feb, 2009 18:57
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Quote from: "libbybapa"Quote from: "Trev0rbr"
why do people peen the precup in since it can't fall out unless its broken?
I've seen pics of several that have fallen in whole.
Andrew
I have a one in my shed that fell out whole, and the engine needs a full rebuild and oversized pistons as a result :evil: -
#11 by Smokey Eddy on 06 Feb, 2009 19:00
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eff man. How old was the head?
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#12 by BellCityDubber on 06 Feb, 2009 20:48
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Quote from: "truckinwagen"
because the G60 is a positive displacement supercharger it will compress the compressed air from the turbo further similar to a compound turbo setup, generating higher boost pressures than either the turbo or supercharger could without taking them outside their efficiency ranges.
A local legend in these parts did a twincharged G6016vT back in the day... he was using the g60 to pre-spool the turbo.... when I had seen the title I figured that was the route you were going to take....
regardless.. a very cool build....
I'll be watching -
#13 by Aki-76 on 06 Feb, 2009 23:19
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:lol:
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#14 by truckinwagen on 08 Feb, 2009 16:36
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well, I got all of the valves lapped, but when I went to re assemble the head I realized that AutohausAZ only sent me four f the eight valve stem seals I ordered, so I was forced to go down to Crapa(because I dont want to wait for more to be mailed to me) and buy the only seals in the state for $3 a piece.
they turned out to be super cheesy, more like a plastic bushing than a rubber seal, I will take some pictures soon and post them.
I will be putting these ***ty seals in the head because I just want the damn thing to run, we will see how well they work.
other than that not much progress other than getting a GTI cluster with a tach to modify to use a sender from a electronic speedometer, which will also be getting a pair of gauges installed in between the tach and speedo where the warning lights used to be(gauges are so much better than idot lights)
more soon!