Cadde's 1.8 turbo Project

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Mykel
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Re: Cadde's 1.8 turbo Project

Post by Mykel » Sat Jan 03, 2015 8:07 pm

Result!

Markus has just posted the pics of the finished manifold on the mgboard.de forum:
image.jpg
image-1.jpg
Nice work, innit?
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Re: Cadde's 1.8 turbo Project

Post by jaydoginvasion » Sat Jan 03, 2015 8:28 pm

Looks awesome!

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Re: Cadde's 1.8 turbo Project

Post by Mykel » Sat Jan 03, 2015 9:28 pm

Yes, Markus is an artist with the welder! I can’t wait to see the thing in the flesh on Monday, when I collect the original manifold. All is fabricated from 4 mm stainless steel, the flanges are 10mm. Has been welded up with a special welding wire for very high themal loads. He’s perfecly sure that this manifold would easily withstand temperatures up to getting red-hot. Although being welded, the weight is the same as the cast iron original.

The most important mod is the recesses for the fixing bolts, allowing the studs on the head to be much shorter, which eases fitting the manifold in the tight area. It was a pain to get the original off. I will be using bolts for the longer holes on the blue TF Turbo when refitting it.
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2004 TF 135 in Monogram Spectre, black leather, RHD
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Cadde
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Re: Cadde's 1.8 turbo Project

Post by Cadde » Sat Jan 03, 2015 10:40 pm

Yeah , uuups , already posted , thanks Mykel !

Ive been busy installing Kubuntu ... takes me two days ... :evil:

he´s an artist ! :thumbsu:

and right , i feel a slight pressure coming up now ... haha ...

now that we have the parts , it´s only putting it together ...

:lol:
fully unfunctional ...

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Cadde
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Re: Cadde's 1.8 turbo Project

Post by Cadde » Mon Jan 05, 2015 10:02 am

yeah , only ... :lol:

waiting for parts and looking for the connectors fitting in these of the photos, the other side , so to say
...
any idea , where to get them , other than cutting an complete harness ?

maybe an part Nr. is available somewhere ?

hmmm, the picture wasnt shown as i quote it , uhhh....

the picture of the plugs i´m holding in my hand at the beginning of the thread ...

Sorry !


Thanks !
fully unfunctional ...

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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Mon Jan 05, 2015 10:08 am

You beat me to it Michael! :lol:

The manifold looks great - and should work a treat :D

BTW, I've made contact with Pure Motorsport regarding the blue car - Michael, I've cc'd you on the correspondence: are they coming through on your gmx account, or are they being held up in your spam filter?

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Re: Cadde's 1.8 turbo Project

Post by Mykel » Mon Jan 05, 2015 10:12 am

Hi Rob,
I have received your emails, but not been on the car again so the detailed questions are still in the making. :lol:

Today after work I will see the s/s manifold live ... can't really wait!
MGTF:
2004 TF 135 in Monogram Spectre, black leather, RHD
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2001 ZR 160 in Solar Red, LHD, LPG conv
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Rob Bell
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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Mon Jan 05, 2015 10:31 am

Mykel wrote:Hi Rob,
I have received your emails, but not been on the car again so the detailed questions are still in the making. :lol:

Today after work I will see the s/s manifold live ... can't really wait!
:lol: No worries! I've asked Nick for any information regarding the work they carried out on the car: the charge cooler for example appears to be aftermarket - I have a feeling that BBR GTi would have used a bespoke item originally...

The s/s manifold does look amazing! Hopefully Cadde can lend me the jig so I can get a manifold fabricated here. :thumbsu:

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Re: Cadde's 1.8 turbo Project

Post by Cadde » Mon Jan 05, 2015 3:20 pm

Rob, please ask Mykel , as i wrote you the jig is maybe still accessable.

Call Mykel, cause he will meet Markus this evening !

that is the shortest way !

To this point i havent got an answer from Markus ...

Call Mykel !

:D
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Re: Cadde's 1.8 turbo Project

Post by Mykel » Mon Jan 05, 2015 7:42 pm

Will you be at Stoneleigh this year, Rob? I could take it with me, as posting it would cost a fortune.


Sent from my iPhone using Tapatalk
MGTF:
2004 TF 135 in Monogram Spectre, black leather, RHD
MGZR:
2001 ZR 160 in Solar Red, LHD, LPG conv
Classic:
1972 MG Midget MkIII RWA in Blaze Red
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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Mon Jan 05, 2015 10:29 pm

Thanks chaps; yes I'll be at Stoneleigh - see you there! :)

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Re: Cadde's 1.8 turbo Project

Post by Cadde » Fri Jan 09, 2015 10:20 am

Here he is !

He´s quite small and compact ! Isnt he ?

Well next week the engine is supposed to be ready to go back in the engine bay !

After/before the snow ... thats the question ... what snow ? ... yeah, what snow ... :|

while frost, i´ll do nothing ... :roll:

but thanks to global warming , i´m really thinking to get this task done , beginning february outside in a polo shirt ... 8-)

small and hopefully mean :twisted: :
made by Rheinkiter .jpg
:thumbsu:
fully unfunctional ...

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Rob Bell
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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Fri Jan 09, 2015 5:03 pm

Nice one Cadde... Now I have to have a look in my parts pile for that spare cylinder head ;)

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Re: Cadde's 1.8 turbo Project

Post by 924Rothmans » Fri Jan 09, 2015 6:09 pm

Looks a great free flowing manifold, really enjoying your thread, keep up the good work :thumbsu:
Mgf

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Cadde
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Re: Cadde's 1.8 turbo Project

Post by Cadde » Sat Jan 10, 2015 11:29 pm

I´m in hell !

SHOOT ME !

I have a broken screw in the turbo head ... one from the exhaust manifold, you name it , i´m screwed ... :roll:

tried to get it out , but no success ... my mates sayin, getting some crazy special tools to get the screw out ...they ve had big fun seeing me sweatning / failing ... :twisted: :lol:

the craziest idea was , to bring the head to a machine shop and let them do the work ...

and it turns out that no humour was involved .. uh , scary , machine shop ? sounds like cheating to me ! haha ... BUT :

cause too much can go wrong , let a guitarist do such a task while the storm under a carport, with two left hands ...

at the end it seems like a pretty good idea ... ( :yeah: ) i dont want to take my money to a machine shop , so i ve instantly decided to go another route ...

ah , and by the way, the manifold was a tiny bit too wide,
too wide.jpg
so ive got somewhat creative and pulled one of my special machines out of my barn ... WW2 special model , it seems ... but runs ...
runs .jpg
and take a look at the remarkable working place , its really fun to work on this "bench" , you never know what happens next , aaannd you never get out of beer ...

im still alive, ok, nothing happens to my fingers and at the end of the fitting process the machine crashed to pieces, haha , but the manifold fits now ... thats been obviously the last job for this thing ...
runs no longer .jpg
so , again : as my buddies having such "interesting" ideas , im now more in the mood to go nuts and rip the MPI head from the block and throw my already skimmed VVC head on it ! :twisted:

It´s really too early in the timeline , but due to the circumstances , i say , what the heck ...

sooner or later , i would have done it anyway , so why not now ... i dont want to invest in the machine shop, so i invest into the future ( in the long term means garbage :lol: )
so on monday ill ask my sponsor ( friend , car fanatic! unlike me ! He will understand ! )
and borrow some money to do it right just now ... vvc solid cam conversion , here i come ! Verniers , yeah ! blinky blinky, ( yeah , im an idiot , say it loud ! :lol: )

we´ll see what happens on monday ...

report follows ...

;)
fully unfunctional ...

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Re: Cadde's 1.8 turbo Project

Post by Cadde » Sun Jan 11, 2015 7:43 pm

hi , here what iv done today , due to the broken manifold screw in the mpi head ...

back to zero :

oilpan and head removed checked the liners , good , no really big things i have to be afraid of ...

ive worked in crying tears cause all was ready to go back into engine bay so now back to zero :
before
before
now it seems to become a complete overhaul ,what is not really is abad thing , when you have the right tools and if you not have to work in the eye of the storm and a big pile of cash to buy all the things needed ... :lol:

i post some pics for your amusement ...
looking good , so far ...
looking good , so far ...
the liners standing proud ... have to measure it in detail
the liners standing proud ... have to measure it in detail
working under the most annoying circumstances , storm, horizontally rain , 3 degrees and my fingers on the cold steel , yeah ! Great ! :twisted:
already a MLS ...
already a MLS ...
OK , only 5 attachments ... but now a serious question as i have a fully portet , VVC head , im now already want to go this way .... but , can anyone point me to how to block the VVC mechs to not need to buy a vvc inlet cam , can somebody help me on that , cause i would love to leave them in ...

a "how to block the vvc mechs in perfect position" tutorial , haha ...

And yes , i WANT to come to the MGFIM ... as you see ... LOL !

4 months to go ...

Thanks !
Attachments
its raining again.jpg
fully unfunctional ...

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Rob Bell
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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Mon Jan 12, 2015 10:19 am

This is what you'll need for the VVC head to convert to a solid inlet cam - a Piper conversion kit:

Image

The above picture is from QED, but you can buy direct from Piper, from Dave Andrews (DVA Power - a good person to get to know in any case!) or from any of a number of Lotus specialists.

Sorry to hear that one of the exhaust manifold studs has sheared :( How much of it is left? By the sounds of things you've probably tried most things to get it out (stud extractors?), but it may need to be drilled out and the thread re-cut :( A machine shop shouldn't cost you too much to do this though.

The turbo head is the same as an MPi head if you want to avoid using the VVC casting at the moment?

What cams were you thinking of using? :)

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Rob Bell
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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Mon Jan 12, 2015 11:50 am

By the way, I have just heard back from BBR GTi regarding their cast turbo manifolds:
BBR GTi wrote:Hi Rob, thanks for your valued enquiry and interest,
Sincere apologies for our delayed reply, following a unit move last year it required a large search to sort though our castings. Unfortunately we have no k-series castings available, we do still have our pattern should there be further interest we may consider casting a low quantity batch of manifolds but not at this time.
Great to have a response, bad that they don't have any manifolds lying around, great that they may be prepared to cast some more because they still have the pattern, but bad they won't be able to do this at the current time....

I am not sure that this is a polite way of saying, "thanks for your interest, but we're not interested"?

Custom manifolds do appear to be the way to go (or modified bulk heads if using the standard 1.8T manifold!)

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Cadde
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Re: Cadde's 1.8 turbo Project

Post by Cadde » Mon Jan 12, 2015 4:04 pm

LOL !

nice answer ...

i´m not in the mood to comment that ...

aaand , yes Rob, i know that the piper stuff is the easiest way to get the job done , BUT :

as a musician , i´m broke , thats the "how to make a 1.8T conversion , without nearly any money" thread and to use all available parts to get it done, is key ...

with money it would be all too easy ... :lol:

this is better than this , is at this point not the question ...

to make it happen with the parts available ...

otherwise newman cams , blanking kit and verniers : i dont know : 800 EUR ??

Nope , this has to wait , as i surely would love to do it ... in the ( near ) future, for sure ... :thumbsu:

So : id love to put the VVC head on it , staying with the mechs and lock them ...

on the exhaust side i need a vvc cam ...

sold my two vvc cams , half a year ago ... 75 bucks each ... uhhh n now i need one ... sigh

and as Koos and Dave Walker stated , to stay pretty standard on cams , i take their advice serious !

i´m in the need of one standard vvc outlet cam, please and how to lock the vvc mechs ! :thumbsu:

me and my buddy took a look to the mechs and its somewhat easy , when the duration range is from "what do i know" to 292 , to lock it in the middle of the mechs working area and call it a ( safe ) day ... you know what i mean guys, as im not sure as i describe it right ...

But how to lock it ? and removable , would be great ...

i thought of flooding it complete with super glue, to hold them in place ! but my buddy instantly screams ... as you would, too ... :lol:

but you get the idea , i´m thinking in solutions ...

and ive found a friend who is on my side to get the screw out of the mpi head !

but , thats another story !

Tomorrow !

4 Months to MGFIM !

;)
fully unfunctional ...

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Re: Cadde's 1.8 turbo Project

Post by Rob Bell » Mon Jan 12, 2015 5:08 pm

To save money, get the damaged stud out of the existing head, unless you can find a replacement MPi head (it is the same casting as used on all 1.8 litre K-series, and also on 1.4 and 1.6 K-series engines - so you might be able to pick up a bargain... because not everyone knows about this commonality!!!)

Running a VVC head is always going to cost you money - and the VVC blanking kit, from what ever source, is going to cost you more! Unfortunately the only way to save the pennies is to keep what you've got, or find something that is very similar to what you have... :(

Shame it looks as though the stud has sheared in the block... :( Might be worth a go with a stud extractor - a drill-based extractor is probably the one to try:

Image

Image

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