Low boost blow through

[DaveSimpy]

Howdy,

Just a bit of an update.

- Drill, tapped sump for oil return
- Dizzy removed ready to have timing locked
- Down pipe measured and cut ready for welder to tack together
- Fitted fuel cut off interia switch in engine bay
- Re-fitted brake servo with modified mouting brackets to hold it closer to the firewall

Just need to get some 90" Silicone bends to attach boost pipes to and from intercooler, mount intercooler, lock dizzy, set advance timing on dizzy, hook up vaccum pipes to wastegate regulator to top hat.

Sounds like a lot but not really. Once done ready to fire it up Oh yeah will need a boost gauge.

Dave

[Craigorypeck]

Found this on another site, good info on a proper dissy setup, could be used on a 4 pot dissy too????

The Ford Capri Turbo Technics kit had a modified Bosch vacuum advance module fitted to the side of the distributor to advance and retard the timing for when the turbo kicked in. The part number for this module is 1237122877...and it was also fitted to Saab 900 turbos's back in the day.



good luck

[jimmyted]

just seen this. very cool!

how you getting on?

[DaveSimpy]

Alright Jimmy Ted,

It's going ok ta.

Fuel system upgrade is completed with inertia switch fitted. I've adjusted and modified the dizzy to limit the max advance.

Need to get the manifold modded slightly by the welder to bring the flange closer to the engine so the downpipe can clear the steering coupling.

Got the downpipe cut and tacked together to test fit once manifold is modded.

Just waiting on my landlord who owns a garage to sort me out with some intercooler right angle pipes for fitting it all together.

Oh yeah also need to mount intercooler using some kind of fabbed bracket in from of radiator.

To be fair once the Exhaust manifold is modded it's just the downpipe.

I'll then start it up and see if it blows through.

Dave

[jimmyted]

Sounds like your getting close! Will be watching this space. I love the fact you’re doing it to a 1.6 too.

I’m a bit of a forced induction dummy to be honest, but sounds like the supercharged guys have got your back! I’ll back up what was previously said about altering the advance curve though. I had to retard the hell out of my 1.6 head on 2.0 combo, cos that just pinged and ran like crap with the standard advance curve. & I wasn’t trying to force anything!

Good luck.

[DaveSimpy]

Howdy,

I fitted this to a 1.6 cuz that's what I had in the engine bay. My reckoning was that all parts are bolt on so if I wanted to go 2.0 route it's an easy swap over and the hard work has already been done. Same goes with EFI as a further step down the road. The 1.6 revs nicely and I do like the idea of it having a little more kick with some low boost.

Exhaust manifold has now been changed to flange is closer to engine. Going to bolt it all together after work, looking like downpipe will now clear the steering coupling.

Refitted the dizzy last night. To be fair once it's bolted together and all vacuum lines are connected plus the oil feed and return connected up there is no reason I couldn't start it tonight.

I'll turn it over a few times with plugs disconnected to get oil flowing to a from the turbo. I will make sure the wastegate is pretty much open till I can fine tune boost.

Fingers are firmly crossed that the oil seal in the turbo is ok and doesn't kick out loads of smoke. The exhaust wouldn't be completely connected up so would make a right racket but for the sake of fun and encouragement I may go for it tonight. Or the light may fail and a walk to the pub might stop play

Either way i'll be happy

[DaveSimpy]

Here are some pics :

Flange has been brought closer to head so downpipe clears steering coupling.



Thinking of mounting intercooler up front in the space between fan\radiator assembly. I think I may drop the radiator down slightly so the pipes can easily clear the top. If anyone has any 90 degree 2" silicone coupling pipes please let me know. They are quite expensive!





Fuse holder and fuse that feeds from power in the engine bay through inertia switch to the fuel pump under the wheel well.



Malpassi carb turbo rising rate fuel regulator to ensure I receive fuel 1 PSI above boost.



Inertia switch for fuel cut out in case of an accident, this is off a land rover.



Fuel pressure gauge attached to return on carb. Return to tank now comes from fuel regulator. Fuel pressure is at 3.5 psi when pump is on, wired to ignition on.



Most work will now revolve around downpipe and mounting intercooler.

[DaveSimpy]

Bit more piping done.

[scherrit]

Looks great pretty inspiring!

[DaveSimpy]

Thanks!

Worth noting that I need to drop the radiator down a few inches so the boost pipes would clear the raditaor enabling the bonnet to shut. Ideally I would like to have the piping going round either side of the radiator but that would require a lot of pipe fab work at great cost for the same result.

Tonight I will be cutting the oil return pipe to the right length and routing past exhaust. Re-fitting wastegate to location higher up on turbo to clear oil return pipe, also lengthen wastegate actuator to hold open wastegate slightly to play it safe with boost on first run.

Might actually start it tonight

Dave

[DaveSimpy]

Hi guys,

Filled her back up with oil last night, finished securing main boost pipes with hose clips. Wastegate all attached and downpipe bolted on for testing ( still need to measure up a connecting piece to main exhaust).

Turned it over a couple of times with leads disconnected to spray the cam a bit. Connected up leads and turned over but no firing.

Battery started to die so it's been on charge today, ready for when I get back.

Was pretty dark by then and was raining. I will check static timing tonight and make sure all leads are securely pushed home. If that's no good then I will check for spark. I think it will just be a case of timing being out as I had to remove the dizzy.

Still need to connect up boost reference from fuel regulator to top hat to increase fuel pressure under boost. Also need to stick a boost gauge in. So if it does start tonight it won't boost as such as there are open connections on the top hat but it would be good to see the turbo spin and check for other leaks be it oil, water, vacuum etc

Cheers, Dave

[BMWcapri]

this is inspiring. if you get problems with the carb not fuelling properly then try a Renault 5 turbo carb, i've seen them still going well at over 200brake. What size is the turbo?

[DCDave]

Look forward to seeing this up and running, good work

[DaveSimpy]

It lives!!

Exhaust not connected up yet so makes a bit of a racket.

Video:

[jimmyted]

congrats Dave! Excellent stuff. You had it out for a test drive yet? Really piss off the neighbours

[Terra-Kotta]

Very nice! more details please.. spark control, fuelling etc

Just stick a compressor on it. That'll be Allright.

[DaveSimpy]

Hi Guys,

Not very exciting update but the welder welded up the down pipe last night that i'd cut and marked up.

Going to fit it tonight then do a bit of measuring done so I can order a reducer pipe off the net.



Cheers

[scherrit]

Wow! truly inspiring....

[DaveSimpy]

Hi Guys,

Another very small update. Modified brake servo brackets to bring servo closer to firewall thus clearing turbo. Need to pick up some locking nuts tonight so securely properly.

Waiting for connector reducer to arrive to join downpipe and exhaust system, hoping this comes tonight:)

Fed vacuum hose into cabin from top hat to go to boost gauge. Gauge looks cool in the cabin but also really important for me during the set up to make sure boost isn't too crazy and literally gauge if there are any boost leaks.

Need to get some DOT4 for master cylinder and make sure brakes work and assuming exhaust coupler turns up I may be able to drive this weekend

Oh yeah, also borrowed a very nice snap-on timing light from mate to make sure advance isn't too mental to guard against detonation.

I'll keep you posted

Dave

[DaveSimpy]

Hi Guys,

Realised I didn't answer a couple of questions.

BMWcapri, it's running a Garrett T3 which came off an old Fiesta RS. Carb seems to be fueling ok now.

jimmyted, No test drive just yet mainly cuz I need to fill the braking system back up. Will get that done soon as.

Tonight i'll get it warm so it actually runs without nursing then get the timing light on it. Then start measuring boost and make sure all safe before going for a test drive.

After dizzy modification I also need to see what the max advance is before boosting

Dave