E150 UOL rebuild - End of project :-)

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Corky
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Re: E150 UOL rebuild

Post by Corky » Wed Feb 20, 2013 9:58 am

CNHSS1 wrote:Steve,
Your cars the same design flipped manifold as Trevors by the way
Thought so, away from the car at the moment so couldn't nip out to check.


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Re: E150 UOL rebuild

Post by td99 » Wed Feb 20, 2013 9:45 pm

Started on te Ex manifold tonight. Made more precise template than that of yesterday.
SAM_0543s.jpg
SAM_0543s.jpg (47.76 KiB) Viewed 1986 times
Flipped it over using the manifold exhaust gas outlets for registration and stuck it back on manifold with double-sided carpet tape.
SAM_0546s.jpg
SAM_0546s.jpg (84.93 KiB) Viewed 1986 times
Cut the outer "ears" off with plasma cutter (not neat!) and tacked then into position on template
SAM_0547s.jpg
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Re: E150 UOL rebuild

Post by td99 » Wed Feb 20, 2013 9:58 pm

Next: set TIG unit to 150 amps, pulsed - hoping for good penetration and finished the job on both sides.
SAM_0548s.jpg
SAM_0548s.jpg (81.93 KiB) Viewed 1978 times
SAM_0549s.jpg
After uloading this, it made me check the state of the weld on the right, but it's just a trick of the light and the "ear' is a bit proud of the flange, even after ";cleaning" with angle grinder.
SAM_0549s.jpg (53.61 KiB) Viewed 1978 times


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Re: E150 UOL rebuild

Post by td99 » Wed Feb 20, 2013 10:08 pm

Interestingly, there is quite some difference in the manifolds.
The dimension marked in photo is
On Cylinder head: 31.4 cm
On XS Power manifold: 31.4 cm
On other manifold: 32 cm, that 6 mm is of course distributed, but giving a definite 3 mm mismatch on outer ports.
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Difference7.jpg
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Re: E150 UOL rebuild

Post by CNHSS1 » Wed Feb 20, 2013 10:23 pm

Manifold ports should be bigger than exh port in head


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Re: E150 UOL rebuild

Post by Corky » Thu Feb 21, 2013 9:29 am

So on eBay it's this one ? http://cgi.ebay.co.uk/ws/380580788240

I wonder if it would be possible for them to supply the manifolds with the flange the right way round.


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Re: E150 UOL rebuild

Post by td99 » Thu Feb 21, 2013 10:10 am

You'd have to find the actual manufacturers - they might even have a bin of "faulty" ones made back-to-front :wink: :wink:


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Re: E150 UOL rebuild

Post by Corky » Fri Feb 22, 2013 4:03 pm

td99 wrote:You'd have to find the actual manufacturers - they might even have a bin of "faulty" ones made back-to-front :wink: :wink:
That would be a nice find !

I'll drop the ebay seller an email, if you don't ask .............. 8)


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Re: E150 UOL rebuild

Post by td99 » Sun Feb 24, 2013 10:42 am

Removed the lower 4 studs and hung the manifold on the head.
Shocked at the ultra-short studs into head, while the head has 20 mm of thread.
Attachments
Lower Studs.jpg
Short ends into the head
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Re: E150 UOL rebuild

Post by td99 » Sun Feb 24, 2013 10:56 am

It's going to be a tight fit...well I knew that but even so...oval downpipe maybe?
IMAG0033sjpg.jpg
form directly above
IMAG0033sjpg.jpg (101.05 KiB) Viewed 1864 times
and with turbo (T28 I think) in place...
IMAG0034s.jpg
IMAG0034s.jpg (97.62 KiB) Viewed 1864 times
and with proposed V-coupling... which will have to be replaced by a more compact design.
IMAG0036s.jpg
IMAG0036s.jpg (112.11 KiB) Viewed 1864 times
I'll consider whether to cut the neck of the manifold to angle the turbo closer to the engine. That could also allow me to gain another centimeter longitudinally.(Need to fit inner wing before that of course).
If turbo is closer to engine than now, the actuator will have to be re-positioned as it will foul the cambelt cover. But should be least of worries.
Or cut the pipes at head to change angle and maybe create more space for downpipe.
I can move the engine about 1 cm forwards too.

Have a business trip this week, so time to consider...
Last edited by td99 on Sun Feb 24, 2013 11:00 am, edited 1 time in total.


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Re: E150 UOL rebuild

Post by Roger Pennington » Sun Feb 24, 2013 10:59 am

td99 wrote:Removed the lower 4 studs and hung the manifold on the head.
Shocked at the ultra-short studs into head, while the head has 20 mm of thread.
That does seem to be a generic TI problem - see this thread


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Re: E150 UOL rebuild

Post by Corky » Sun Feb 24, 2013 11:06 am

Trevor, do you want me to take some measurements ?

Best photos I have are these, but can take some more if it'll help.

Image
Image
Image
Image
Image


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Re: E150 UOL rebuild

Post by CNHSS1 » Sun Feb 24, 2013 11:16 am

i think your bulkheads been 'tickled' a tad for clearance Steve.

TD
you may have to have a look to see what can be trimmed of the bulkhead without disturbing the heater box/matrix.

alternatively, can you not spin the turbo through 180degrees, so the exh housing faces forward? that way you have room to have a nice curving 180deg downpipe and keep the nice V Band fitting, pass under turbo and out through chassis or over chassis rail? induction tube would then face rearwards and could be piped wherevere preffered to the AFM and filter a bit like the OEM setup with a coily trunk pipe

Jetex do some nice tight 90 deg bends which would help, ceratinly tighter than Steves setup, may even get away without bulkhead mods if the 90 deg bend is attached directly to exh mounting flange (dont think youll get the V band in there too.


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Re: E150 UOL rebuild

Post by reliant-reviver » Sun Feb 24, 2013 3:51 pm

Loose the V band coupling, go for a standard flange into pipe arangment and it should be ok? What diameter of exhaust are you looking at? If you are after a specific bend or size, I can check what I have here in stock..... not sure you'll manage to do it all with bullbars!


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Re: E150 UOL rebuild

Post by td99 » Fri Mar 01, 2013 8:10 pm

Just back from Monday-Friday USA trip, cattle-class with KLM/Delta (don't think you can sink lower!)

Thanks Steve, Craig and Phil for photos, comments & advice. Some good ideas there. Need to take some time to re-consider/measure etc.
Had intended to start with standard exhaust, but with ability to increase diameter.
My conundrum here is that I'd like to get the car assembled and imported to NL asap, before there comes some new legislation that prevents it, but don't want a permanent compromise.
Watch this space, but don't hold your breath!


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