My Turbo Build

[Delft Maloo]

Hows it going everyone, some of you way have known about a little project ive been working on for some time for my ute and i thought id finnally get some pics up of some of the stuff so far.

Earlier in the year i brought a pair of high flowed to4's from an ls1 member, these turbos graced the commodore psi355. i have since brought one of the turbosmart progate 45 wastegates off shane aswell. all work done so far has been mostly completed by myself, but ive had a hand on a couple of things from my mate jeremy and from dale(10secrx7).

Im working hard to get this project running in basic form by the drag day coming up shortly.

http://i205.photobucket.com/albums/bb105/tkwpalm/pty017.jpg

http://i205.photobucket.com/albums/bb105/tkwpalm/pty018.jpg

[Delft Maloo]

http://i205.photobucket.com/albums/bb105/tkwpalm/pty015.jpg heres some pics of my maloo and intercooler corehttp://i205.photobucket.com/albums/bb105/tkwpalm/Photo0046_000.jpg

[BOMI]

Looks good Tim :yep:

Are you doing it all yourself? If so then Kudos to you man :yep::yep::yep:

Keep the pics and info coming!

Troy :)

[Delft Maloo]

About 95% of it will be done by myself. Ive had some advice from a few people which helps a bit cause ive never done anything like this before. It looks pretty simple at first but if you dont have the skills or tools it can become quite frustrating.

Im getting a welder for my birthday a few months ago has certainly helped me in the whole process otherwise i would have had to get it all done for me. i have to pull it all off and start welding it up. Im gonna try and get the oil lines tapped in this weekend aswell so it will beanother step closer to being done. the expensive part is coming up quickly thats the fuel system.
Ive got rego at the end of the month so funds are getting quite short to have this thing finished in time.

[Delft Maloo]

Hi everyone im still going on this. Today i did some more welding on the manifold so its should be finished by next weekend, most importantly i made a start on my oil fittings in the sump. not an easy job in a single garage when doing it all by yourself.

I borrowed a mates engine crane to lift the motor as much as i could and dropped the crossmember as much as possible. It all went pretty smooth, there was a few bolts that were a bit hard to get to but once i got them it was full steam ahead. I only encounted 1 real problem and that was with the sump gasket, i have seen before that it is recommended to use the existing gasket as it is riveted in but on mine the rubber seal had come away from the rest of the gasket in a few places so that means im up for a new sump gasket aswell.

I fitted 3 oil lines in the sump, 1 oil out and 2 returns. why put 2 returns in when im doing a single kit? well once im done with this kit there will be a different designed single and a twin kit coming after i test this one. its much easier to put the extra fitting in now when the sumps off then to do it again when i build the twin kit.
http://i205.photobucket.com/albums/bb105/tkwpalm/sump012.jpg.

http://i205.photobucket.com/albums/bb105/tkwpalm/sump010.jpg.

http://i205.photobucket.com/albums/bb105/tkwpalm/sump009.jpg.

http://i205.photobucket.com/albums/bb105/tkwpalm/sump008.jpg

[BOMI]

Looking good Tim, I am learning alot about turboing V8's via this and a few other threads at the moment.


Troy :)

[DaveHAT]

Fair effort to say the least ... DIY in a big way.

Good on ya for giving it a crack. :bravo:

Keep the pics coming.

[Delft Maloo]

It wasnt to easy pulling the sump out on my own, I had to dodge the engine crane, body stands, jack and try and grab the right tools for where i was. while doing this i wished i was a freak with 3 hands as that would have made it heaps easier.

My big head is full of wonderfull ideas and im just trying to get some of them out to enjoy. i have to thank dale for alot of the knowledge he passed on to me befor i started. At first i was looking at buying a couple of near new gentt turbos and getting the rest semi custom done and with some advice from dale he said give it ago yourself.

Now here i am half way through something i never thought i would actually do.

[Delft Maloo]

Got some new toys today and some more coming hopefully tommorow. 1 walbro intank pump turned up for the ute, 1 k&n air filter for the turbo and a gfb boost controller(temp till i can afford an eboost2).
Tommorow hopefully i should get 8 60lb injectors and a 7psi wastegate spring. gotta try and figure out the hpt settings for the 60lb,ers to run properly.

The ute goes into the exhaust place tommorow aswell to get the dump pipe made and finish off some welding that i ran out of time to complete. There is only one part of the manifold that i didnt get finished and that was on the cross over pipe where it connects to the turbo manifold.

I spent all day(didnt go to work, lucky my boss is my dad) trying to make a pipe section to fit that spot but after 8 peices of pipe being cut and ground i could not get it and gave up:headbang: . Once the dump pipe is fitted and mated up to the system it will all come off for sand blasting and painting.

Have run out of money so that means the intercooler wont get finished yet and ill be running unboosted for a couple of more weeks. But atleast all the hard work is done and then it will be on to tuning my first 2bar setup:yep: .
cheers tim

[SSUte01]

Have you got the manufacturers data on the injectors

ie - actual flow rate at what pressure eg 60.5lb (or cc for that matter) @ 3Bar
- Min PW
- Any other data

It is unlikely that you will get that info as for whaterver reason it is hard to get a hold of for almost every aftermarket injector except a few.

Also what fuel pressure do you plan on running, good idea to test with guage anyways.

If you can tell me the data above at a minimum your Fuel Pressure (Rail) and Injector rating I can tell you most the tables that you need filling in and the ones that may require a small tweaking to optimise the specific injectors you have.

Cheers

[Delft Maloo]

A quick pic update with some more later tonight.
From this large core to this.
http://i205.photobucket.com/albums/bb105/tkwpalm/pty022.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/P1020126.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/P1020127.jpg

[DaveHAT]

Tim ... looking at the cooler pics, does this mean the maloo is now SANS A/c?

I can't see the condensor.

[BOMI]

Looking good Tim :yep:


Troy :thumbs:

[Aeron]

Mate, 10 points for giving it a go yourself!! Looks fantastic so far!!

Good luck with it and keep us all posted.

:)

[Delft Maloo]

Tim ... looking at the cooler pics, does this mean the maloo is now SANS A/c?

I can't see the condensor.

A/C still there just a little modified to make room. Losing the a/c was a price i was willing to pay, but im thankfull i managed to keepit in there.

[10sec_rx7]

looking good mate!!

what size are those fittings you put in the sump? they look pretty small, they need to be 1/2" minimium, 5/8 is more where you want them to be

Dale

[Delft Maloo]

looking good mate!!

what size are those fittings you put in the sump? they look pretty small, they need to be 1/2" minimium, 5/8 is more where you want them to be

Dale

yeah on advice i have allready increased the size to 5/8" about the day after i had put those in. installation starts today and its got to be all done and tuned this week, it shouldnt be to hard seeing as everything is all made now and just sitting in the garage waiting to go in.
Thanks for the advice you have given befor and during the build dale:yep: .
cheers tim

[10sec_rx7]

no probs mate,

if you need anything you have my number

[Delft Maloo]

the good news is my car is up and running and ive completed stage 1 in time for the circuit day:bravo: . the bad news is i wont have time to update the story and photos till i get back from wakefield. the last few days i have been pulling my hair out stressing about wether it will be finished in time and thankfully it is:yep: . all i have to do now is tune the baby.

[Quadcams]

Good effort mate having a go yourself, hope she all works out like you hoped.

[Kyle]

Still running good mate?? :D

Does it snore as loudly as you do?? :D:D:D

[Delft Maloo]

still running:yep: . i need an oil catch can setup though and a better lsd. im driving it down to melbourne next week for work so i better get the tuning finished so i can get some good economy. i averaged 11.4ltr per 100klm on the return trip from goulburn sitting between 110-125klm/hr so its not to bad considering:) . i reckon i can get it down to low to mid 10's or possibly a 9 on the highway. i have to finish updating the build so far:headbang: .

[Delft Maloo]

Well its been a whole 3 months since i updated this thread so i thought i better get to it as ive played with it for a bit and have since done some more work to it. Well i finally got the turbo kit finished on 21st of sept and headed straight to wakefield park after my sister's wedding on the 22nd. Once there i realized that i aint mark skaife and never will be. Well i found out that std commodore power steering doesnt take long to boil when pushed and that my diff doesnt like the extra power of the turbo. For some that might not have seen here's a vid of ian luff flooging my ute http://www.ls1.com.au/forum/showthre...ghlight=psi355 . i still had stock valve springs in it then so revs were capped at 5g max as it died in the arse from then on with the turbo on it.

Well bettween then and xmas nothing really changed except for continual tuning when i had time and racking up the klm's for work in it except for the hail storm that hit sydney in earlly december while i was working at wsid for the top fuel event, weel suffice to say the ute copped some nasty unimprovments in the bonnet,roof and gaurds, luck enough i just picked up a monaro bonnet off tigerss on the trip down so its now going on sooner rather than later.

As i was getting married just after new years and one of my best mates vyss2ute(adam) was coming down i thought it would be a good time finish tuning his ute and do some upgrades while he was here. I tossed around the idea of doing a cam swap but i didnt have the $ to put towards all the extra stuff suited for the job so i ordered 2 sets of patriot springs of oztrack(steve) for both our utes. i enede up with the extreme's and adam got the gold's. We got such heavy springs cause we allways planned to do cam swaps later and the cams we looked at were pushing the limits on the 918's ect.

The wednesday before xmas i got a call from my wife to be saying we had come across some extra money and that it would pay for most of the wedding leaving all the money i was earning of the xmas new year i cound keep.

This is where the fun started, i had some cash to blow and couldnt figure out what to spend it on and my partner said i cound do my cam but i thought with the $ availible i could skip that all togther and get something badder. I had my mind set either a 8tb setup or a large single plenumn manifold for the ute and i was keen to go till i rang around. The $ didnt scare me but the advice given from some great guys(dale-castle hill exhaust and Christian from russo performance) took my dreams away and saved me some dollars atr the same time. after these guys both gave me the same advice for my boosted application the idear of a flashy manifold left my mind, what was quite funny about this is the 8tb or single plenumn manifold i was going to buy was one of the russo perforance items and they talked me out of it and them selves of a couple of extra $ too thats what great guys they are.

Back to them cam i went, i had spoken to wade cams about a turbo specifice cam for my ute before, so i rang them up on the thursday befor xmas to get one shipped staright away, well to late they had cleaned the machines and idnt have one on the shelf for me so i thought stuff it id call up russo and see if they had anything in stock they could send me, what i got was What cam would you like and ill have it custom made straight away! Well i was shocked and said no chance its thursday arvo 4 days or so before xmas, christian said dont worry ill get it done. Well after some disscussion about specs i we settled on a cam, then i said ill need a 25%udp and belts, double row timeing chain and the nessacery seals for all this stuff to fit, just to spice things up efor the weekend aswell and chris said no probs. Lunch time tuesday i called russo performance to see if they were actually able to get any of it and chris said they had just picked up the cam and the other gear would be hear in a couple of hours, dam theses guys are good. My next drama was how do i get it seeing as i wouldnt be in sydney till the 27th dec and the chances of it making it out here by fright in time over xmas new years was nearlly impossible. lsx438 came to the resque and took the goods home for me so i could grab them off him when i flew into syd and not to be done there he even picked me up from the airport and delivered me and my goods to my destination.

New years comes and ive finished my work requirments which saw me do 1800klm's in a truck, 1 solo speed way bike championship round, 1 world series sprint car round and 3 plane trips and i was home and ready to get stuck into the upgrades and the wedding over the weekend too. Befor adam got here i set about stripping the ute so we could get straight to it. Ill leave out all the tech details as they are the same as every other cam install thread on here. One thing we did do is make up our own valve spring compressor tool which worked fantastic and only cost a couple of $ in bits to make. Well the cam is in the double timimng chain is on and the 25
p too. then we got stuck into the springs and once we got a couple done the process flew by and took us just over an hour for the whole lot of springs, over the next few days i slowly put the ute back together and and got it running and started tunning.

The utes in the panel shop getting the required damages fixed and some extra work and some personal touchs done to it aswell.

Befor anyone ask's i dont know how much power it now makes and i didnt knopw how much power it made befor i put the cam in it either, it hasnt seen the dyno since march last year at castle hill exhaust where it ran 237rwkw with extractors, catback, orrsom otr and my conservative tune. If im lucky and get my ute back this week ill be down in sydney working on saturday and if possible on the way home ill try and stop in at the kandos hot rod car show and try and get it on the dyno there to give me figure to work from as i continue to tune it in.

Thats enough typeing my fingers are sore and most of you ahve probly given up allready anyway, ill update some pics of the ute when i get it back from the panel shop.
cheers tim.
Heres me mate adam putting in some hard yards.
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0113.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0117.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0116.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0118.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0122.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0120.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0124.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0115.jpg
http://i205.photobucket.com/albums/bb105/tkwpalm/IMG_0128.jpg
A massive thanks has to go to my best mate adam, chris and duncan from russo performance and my new wife katie for letting me do this over the week of our wedding

[Delft Maloo]

Here is how the ute stands at the moment, we will see how it looks at the end of the week hopefully.
http://i205.photobucket.com/albums/bb105/tkwpalm/ss003-1.jpg

[Duffman]

Nicely done Tim. Thats a bloody good effort tackling that yourself with only a little help along the way. The ute is looking very nice.

I have alot of admiration for people who just give this stuff a go themselves. There's no way I could do that. I'd get frustrated just thinking about such a large, complicated task.