Torq's big turbo build part II

[Torquemaniac]

The build started in April 2014 and I thought I was done by the end of september (2015), but I was wrong!

After the build, the engine was running great, but it was in need of a professional tune...unfortunately I was out of fund and the weather was getting hugly out here (freakin Canadian winter)

In the meantime, I did some basic tuning and saw some limitations of my setup that needed to be addressed before I get a pro tune

But even with my unsettled setup, I could not manage to decline some racing fun, and this led to what seems like broken ring land (low compression, high crankcase pressure...)

Part II of the build will be documented here, but the first post will be a recap of part I in pictures...

 

[Torquemaniac]

 

[Torquemaniac]

Now on to part II

When I first monitored high crankcase pressure (7+psi), I thought that the opened up ring gap (0.014 first ring, 0.019 second ring) was to blame, so I made a crankcase evac system that required no maintenance (and hopefully pull some good vacuum on the crankcase)

Here is the diagram of the system

The system work as follow :
- Crankcase pressure (blow-by) flows out of a custom made oil cap breather (with a high-flow coalescent stainless filter)
- Blow-by goes through a BMW cyclonic air/oil separator
- Oil is drained at the bottom of the separator to the oil pan
- Cleaned air is pulled through the intake

The oem PCV valve and valve cover breather are connected together with a T adapter to equalize crankcase and valve cover pressure/vacuum..., and a gauge will be plugged on the other port of the T adapter to monitor pressure/vacuum

Since I wanted the system to pull some decent vacuum, I fabricated a 4'' intake with a super duper venturi section

A floating ball check valve was also fabricated to prevent siphoning oil from the pan (just in case)

Mock-up of the system:

Floating ball check valve :

OIl cap breather:

Intake pipe with super duper venturi :

 

[Raider]

Amazing build, my friend!

 

[Maisonvi]

I consider myself a fabricator, but you my friend have me beat and then some. This is impressive to say the least.

I look forward to see where this all goes.

 

[squats]

Amazing build. I remember following this on the other forum and was in awe the entire time.

I can't wait to see where you take this. Very impressive work.

 

[Slow6_pl]

Subbed for Jealousy of fabbed parts and awesome ingenuity!

 

[nekret]

Holy hell! This is one of the most interesting builds ever!

 

[Ozynigma]

Subbed to see if you ever get this bastard finished

 

[SharksInSpace]

Holy shit, dude. Fab skills on point! That shit is impressive.

 

[Torquemaniac]

Subbed to see if you ever get this bastard finished

LOL...give me some more cash and free time and I will make this 500hp build a thing of the past

Right now its freakin cold here (-20C this morning)...the minute the weather gets more decent, I have a list of issue I need to take care of :
- Leaking valve cover gasket
- Leaking turbo oil drain line (the rubber hose section is not up to par)
- Wastegate spring is too soft
- Air/oil separator is letting oil pass in the intake after 20psi

For the wastegate issue, I will hook a pressurized line on the top port of the wastegate to act as an air spring...I will use a pressure regulator to dial the right pressure in the line (0-30psi regulator) and increase wastegate spring pressure as needed

For the air/oil separator, I plan on getting rid of the BMW cyclonic separator...I will mod the stock valve cover internal breather and hope it perform better than the BMW unit

Got some secret project also for the transmission
[doublepost=1484011765][/doublepost]To keep this thread up to date, here is the ''documented'' engine rebuilt after monitoring excessive crankcase pressure (up to 7psi) and having the dispstick pop

Opened the engine and bingo...piston 2-3-4 have broken ring land, and injector seal 1-4 are leaking...two ring land have broken on the exhaust side, and the other one is half way between side and the exhaust side (carbon buildup on the top ring ends shows that the ring did not butt!)

Fortunately the broken ring land remained on the pistons and the cylinders are in perfect condition...however, before another piston drop-in, I will hone the cylinders to start fresh (just enough to deglaze the cylinder and make a nice cross-hatch)

Fabricated a honing cap to prevent debris from contaminating the crank area...tested it today and it works like charm...it sit perfectly on the casting recess after the cylinder sleeve, and leaves about 4.75 inches of cylinder depth for the honing (only about 0.50 inch at the bottom of the cylinder wont be honed

[/IMG]

List of the rebuilt :
- New genpu pistons gapped at 0.018 and 0.022
- Toyota injectors seals
- Upgraded to direct port meth injection (4 X 0.6mm Aquamist nozzles for 16.5GPH/100% meth)
- Upgraded to a 3.12ID blow-thru MAF housing (good to 67lbs/min according to my MAF cal)
- Painted the turbo CHRA and turbine housing with ceramic paint (because Holset like to rust)

Also fabricated a digital overboost protection system (digital pressure switch with a Mosfet driver module and MAC solenoid)...the controle module is fixed on a bracket that is attached to the fuse box

The system works perfectly...with it activate, it feel and sound like a blown silicone coupler...the pressure release is insane (the sound is pretty obvious with a vent to atmosphere BPV)

After the engine breakin period was done, I cranked the boost to 20spi and tested the car 0-60 time...managed a 5.6sec 0-60 bI only brake boosting to 18psi because the brake started slipping at that point...I could have probably improved the time by revving higher and reaching 60 in second gear, but im just lazy and didnt try it

Snapshot of the Versatuner graph (0-100 in km/h)

Attached are CSV and Versatuner log of the run

After this I started to inject meth and scaled the MAF to compensate for all that auxiliary fueling....now run about 27-28psi boost (unfortunately using the overboost protection system to control the boost spike that I get at every gear change...the freakin TCM pull ignition timing to the minimum during gear shift and this fires up the turbo...too bad we dont have acces to the TCM tables )

 

[Alpha Wolf]

Impressive fabrication. What was the cause of the broken piston ring lands?

I am really happy with mine after my pro tune.. Made a huge difference.

 

[Chris wills]

Which spring is used for this upgrade? and how much does it help? thanks