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malibuguy
malibuguy HalfDork
9/9/22 8:27 a.m.

The last handful of days have been stressful.

Bought a Maxpeedingrods 'GT28' to try to finish the season off and experiment with a larger turbo to see if its a path worth pursing.

After spending a whole day modifying, prepping and fitting the turbo...turns out it was machined wrong or something.  Spins freely when cold, but after approximately 10seconds of run time it locks up.  Once it cools down it spins again.  Fire it up...10seconds later locked up.  Rev the piss out of it...doesnt matter.  Its like they didnt compensate for thermal expansion.

Before you react.  I KNOW its a china turbo.  I didnt expect 100k of use out if it...but more then a minute.  I really only wanted it for a month or 2 for testing and use.  

So I then realized my pair of Garrett GT1548 turbos I bought about 10 years ago (i seem to have bought alot of turbos 10 years ago) also had a t25 inlet flange I quickly picked the best one and began making it work.  Quick look at the compressor map and I should be just within the sweet spot but near out of turbo.

I had to make a downpipe flange since I didnt want to wait.  That also meant I had to make another downpipe.  So I whipped one up with some left over aluminized steel mandrel bends.  I am not a fan of silicone bends but for now I am using one just to make things work.  Also had to make a new intake pipe.

BUT it works...and rather well surprisingly to me.  As expected the much smaller turbine responds VERY well and doesnt feel like its choking it off that bad.  That being said its very OEM feeling but definitely not an open lapping turbo. 

Right now I am trying to remap the boost controller...as it wants to go to 21psi of boost...it has a very small wastegate port that I ported as much as I felt comfortable with.

I also have some thermal zero products coming to control the heat.  After my first test drive I realized how much spooly noises this turbo wanted to make.  So i removed my Dynomax SuperTurbo muffler and made a new rear section using a Flowmaster resonator from a Tundra exhaust kit.  Makes it sound like a SRT4 in a good way.  Very deep, throaty and gargles, motor sounds like its got a big arm.  And all the spooly noises.  Best part.  Absolutely no drone.

 

malibuguy
malibuguy HalfDork
9/10/22 3:47 p.m.

Annnnnnd sent a rod out today...

V6Buicks
V6Buicks Reader
9/14/22 12:59 p.m.

crying

Noooooooooooooo!  What happened?

jfryjfry
jfryjfry SuperDork
9/15/22 12:45 a.m.

Oh man, just one day later!   I guess you found the upper boost limit

malibuguy
malibuguy HalfDork
9/15/22 10:56 a.m.

Yeah just confirmed the skinny rods do not like high boost.  Found that at 18psi with a K04 on the other car.

Just couldnt get the boost to come down from over 20psi due to the super small turbine and small wastegate.  I was like I should yank the manifold and put on my external gate before I blow this E36 M3 up...next pull Uncle Rodney showed up

malibuguy
malibuguy HalfDork
9/30/22 9:48 a.m.

Drove Floyd today to celebrate Earl being featured.

Earl is not completely dead...it actually still technically runs.

I have plans to finally either use gen1 internals or go complete gen1 swap.  At some point during the winter I will yank the motor and try to make 1 out of 2...with the set of gen1 rods and pistons I have.  Gen1 rods and pistons give me a theoretical 250hp capable bottom end...however gen2 or "DIS" engines are low revving so the HP is not divided by as much RPM plus they make a boatload more torque.  So likely I will not be able to reach the 250hp number safely...however that is not my power goal ultimately.  Also I will gain a touch of compression as well which is wanted.

malibuguy
malibuguy HalfDork
11/1/22 7:31 p.m.

Finally took the motor out today.

Feast upon the carnage!

 

After I got done taking those pics I noticed rods 1 and 2 were slightly bent as well.

So the current plan is to have this head serviced and redone and plop it onto the gen1 5efe that I have been sitting on.  I do not want to get into putting a bottom end together now.  So Ill save that for hopefully the other block and at some time do a full build potentially.

1SlowVW
1SlowVW Dork
11/2/22 4:55 p.m.

You need a 20psi "safety " boost gauge. That way the motor doesn't know it's getting too much boost and will keep the rods straight. 

malibuguy
malibuguy HalfDork
11/2/22 9:05 p.m.

Didnt get the head off today instead I got cleaning and weld happy.

 

I welded all the seams around the lower control arm mounts.

 

Then I decided the rust will never get fixed unless I force the situation.  So I cut out the rot on the driver side.  Already began a patch panel.  Considering I am definitely not a sheetmetal man...I am happy with the patch look soo far.

 

I will dive into that a little further tomorrow.  I also need to repair some of the inner tub bit and then recreate the fender lip and make the forward patch

metty
metty Reader
11/3/22 12:51 p.m.

that patch looks great from here!

malibuguy
malibuguy HalfDork
11/3/22 8:49 p.m.

Only did a little more.  Got the inner part patched up.  Also made the front patch.  I want to head over to Eastwood to get some sprays for the inner parts I cannot get to once its all welded up.

 

Then I took the rod out...which required some brute force because it was the cap nuts that hit the bottom of the bore which actually bent the bolts inward pinching the cap...so I had to hammer it apart.  Bearing was alarmingly in good shape other then an obvious spot where after it took on damage from the rod letting loose.

 

Intake valves made contact for sure on the piston so they are bent.  

 

 

malibuguy
malibuguy HalfDork
11/27/22 1:15 p.m.

A couple weeks ago I got the head back from the machine shop.

They decked it, competition valve job, also backcut the valves.  Set the clearances, little looser for the exhaust to compensate for the heat.  Also installed my gen1 valvesprings.

Got it on the motor with ARP head bolts, I used a FelPro gasket to try, they claim same thickness as an OEM.

Also discovered the oil pump swap is not going to work as originally planned.  Gen1 has the oil pump Oring groove on the pump with a flat surface on the block.  Gen2 is reversed...the groove is on the block with a flat surface on the pump.  So putting a G2 pump on a G1 block leaves me in a no groove situation.

So I ordered a new OEM G1 pump and an external trigger wheel then got busy in the shop so nothing new.

 

malibuguy
malibuguy HalfDork
12/24/22 1:46 p.m.

Small progress

Got new 15x9s to try on the front and they will fit with a small spacer.  Going to order ARP studs and after the new 245s are mounted, I will dial in the fitment 

 

Got the damper back from balancing.  I am using a heavy factory 4efte unit, but it was slightly damaged and I wasnt sure what the trigger wheel was going to do.  Id say it was $30 piece of mind plus it did need some drilling.

 

I also made an inlet for the new (used) turbo.  It originally had a weird flanged inlet.  I made a flared transition and welded it to a 2.5" piece then welded it to the housing with a slight gap at the inlet.  Ive since smoothed the welds (was not going for perfection knowing I was going to smooth them).

 

I also welded the wastegate shut then also grounded out the flapper arm to gain turbine discharge airflow.  I forgot to take a pic of that.

I also started on the new micro-tubular manifold...no pics yet.

chiquito1228
chiquito1228 New Reader
12/24/22 2:20 p.m.

15x9 with a 245 on a tercel can't wait to see that. Its going to look so good

malibuguy
malibuguy HalfDork
12/28/22 7:44 p.m.

Motor is in, I made the new sensor mount and i have been chipping away at the manifold

malibuguy
malibuguy HalfDork
1/4/23 10:25 p.m.

Well its alive and runs....i have wayyy more time in this lastest iteration then I could imagine.  Still gotta button it up and set the trigger offset.  I got lucky the 3rd number I threw in there was close enough to fire it up

 

Also confirmed the 245/40 on the 15x9 will work with just a minimal spacer

CyberEric
CyberEric Dork
1/5/23 11:50 a.m.

Wheels look good! 

Sorry about the rod, damn that thing went sideways!

malibuguy
malibuguy HalfDork
1/5/23 5:48 p.m.

Got the car running pretty good today.  Still got to refine the tune, refine the engine bay, make some lines, redo some lines, etc etc

Funny thing to me is the trigger offset with the OEM was 265*, the new external trigger wheel required offset is 229*...the same as the size V6 that was in both my 82 and 83 Malibus.  And well 265 was Chevy first sbc.  Just amusing coincidences.

malibuguy
malibuguy HalfDork
1/14/23 3:56 p.m.

Been fighting an odd igniton cut issue.  Which I can only attribute to the tiny bit of runout with my trigger wheel.  For whatever reason I cannot get the tooth logger to work on TunerStudio so it was hard to chase what the issue was.

Today I adjusted the wheel to minimize it as much as I could and it seemed to improve things to the put where I can beat on it a little more and properly feel the new combination out. 

The torque curve is so much smoother and feels fat..hard to say if its the micro tube manifold or this series turbo but I like it alot.  Only running wastegate pressure which is around 7psi.

I got new street tires for my 14" wheels, got Westlake RP18 Tourings and they ride really well.  I almost forget it has a high spring rate.

I have a new set of injectors I plan to stick in and then also refine my trigger set up.  Then I should be good to crank things up.

malibuguy
malibuguy HalfDork
1/18/23 10:17 p.m.

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