Restoration diary / 30-10-2005

30-10-2005 >> Turbo time!!!!!!!!!!!!!!!!!!!!!

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30-10-2005 - For a long time I thought I needed a 1300 as an engine, with a nice head to create the HP the Van needs. Somehow I got to think of using a turbo on a 1000, to combine good mileage and torque/HP. Probably because the 1000 in the red Mini, in combination with a MD 266 cam, is a very nice engine. It just lacks HP...

I bought an almost new Garrett GT15, used for about 1000 km on a Volvo S40 diesel. This is a modern, small turbo, good for up to 220 hp, excellent for the Mini. This turbo is much better than the T3 as used for the Metro turbo. The small size makes sure that it spins up much faster, giving torque at lower revs. The GT is of a newer design, which should help too. Also, it should be possible to fit it without adding a box to the bulkhead.

Here you see it in the position I first thought it should be in. In this position, the manifold right after the turbo cannot be used. This manifold has a 2" diameter, this should fit the exhaust perfectly.

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30-10-2005 - Same setup, from the side. With this setup there will be a problem with the top engine steady. It would go through the red part on the turbo.
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30-10-2005 - Total depth of this setup: 14cm.
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30-10-2005 - To be able to use the turbo, the mounting flange for the actuator had to be removed. The mounting flange can be seen on the right bottom of the photo.
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30-10-2005 - New mounting position for the turbo. Tilted anti-clockwise for a bit, intake pressure side turned downwards, exhaust manifold flange vertically.

You can also see the start of the exhaust manifold. On the next pictures you can better see the work I've done.

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30-10-2005 - Exhaust manifold. On the right you see the pipe as used for the two center cylinders. You look into the pipe that leads to the 4th, right-most cylinder.
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30-10-2005 - Exhaust manifold from another side. It's made from 6 different parts: 4 90 degree bents, flange (piece from the hoist I have in my garage) and a straight piece of pipe. Internally the manifold is flowed for optimal results. The pipe diameter is very small (1 inch, compared to the 2 inch exhaust), to keep gas-flow at a high rate. This will help speed up the turbo sooner. The inside and outside of the manifold and turbo will be coated with a ceramic coating for 1) keeping under-hood temperature down and 2) to keep exhaust gas temperature high for extra performance.
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30-10-2005 - Manifold flange, hand crafted, 8mm thick.
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30-10-2005 - Another look...
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30-10-2005 - A big step in the completion of the Van: The hood is welded in place. Finally!!! I'm almost happy with the result. It could have been better, but just not in my hands...
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30-10-2005 - At the window side of the hood, I created an gap through which hot air can escape. The turbo will be creating more heat, so this should take care of letting it escape.
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30-10-2005 - A wider view of the gap. The gap is right in front of the window, aerodynamically seen a high pressure point. I wonder if hot air will escape through this gap, or if cold air will enter. I guess I'll have to wait for a test to get the final answer.
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30-10-2005 - Another view of the gap.
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30-10-2005 - Bulkhead modification. Normally you add a box here to make room for the turbo. In this case that is not necessary, but I think I can use all the space I can get. If only for the airflow...
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30-10-2005 - Next step(s) for the exhaust manifold.
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30-10-2005 - Recently, my local DIY shop had this small, light blue bench-vice on offer. It's the smaller brother of my bigger Heuer and it's cute! It makes the big one look like a bully...