Fitting a TD06 - 25g to an RVR

[Benzo4gT]

Well, I bought Jamo's TD06 - 25g and a manifold (Thanks Jamo :thumbsup: ) and because I have a W/A intercooler, the exit pipe needs to point upwards much the same as an SSG does with the TD04.

The 25g is not a small turbo, it does fit if using a front mount like an evo 3. After rotating the front cover it was obvious it needed a different approach.

Other threads have pointed out the uselessness (<----that's a lot of S's) of the 7cm2 Kinugawa housings wastegate, and that made me decide to go external, so I ended up getting a section of 60mm

steam pipe in a 90º bend and cut it at an angle that put the turbo a bit lower and further away from the block. I cut a flange to suit the turbo and welded it on.

I gave the manifold a bit of a tidy up and opened up the turbo flange area as well as port matching the head flange, you'd be surprised how much of a lip there was. I decided to

weld directly to the manifold because making another flange by drilling a million holes in a circle and then die grinding it would have sent me insane...er. :wacko:

Gave the ex, mani. pipes a paint before I wrap them but left the extension as I'll be welding on the WG flange as soon as I decide which one will fit.

In the end I ended up with a turbo that fits nicely and a place for an external wastgate :thumbsup:

It's function over style, and a little rough if you look hard at it, but I think the turbo draws the attention away Oh, and the only colour joiners I could get were blue :fuuuuu: I'll have to get black ones

at a later stage, the intercooler pipes will get blacked out.



Next up, a dump pipe!

 

[DOUGMO]

well done mate. good solution. not having to deal with the internal gate may allow you to run a touch larger down pipe too.

are you going to weld the internal gate shut?

 

[vr401]

Good job mate. Looks great.

 

[Benzo4gT]

are you going to weld the internal gate shut?

Yeah definitely, I'm looking at cutting the part of the housing that protrudes and giving it a good weld with some cast rods, but I'll also plate the dump pipe flange to make sure.

By getting rid of it I'll get a bit more distance from the radiator and thermo fan.

The housing sits over more than what it looks like in the pic, but the tab is the part that sticks out the most.

I'd like to fill in the WG opening to make it follow the same lines as if the housing was cast without a WG, but I think I'd be tempting fate doing that, I'm not sold on welding cast for a location like that.

I don't think it would make much difference anyway

 

[evo-gsr]

Fuck yeah. The mad scientist strikes again!!

Looks awesome man.....cant wait to see how this thing goes once you fire it up!

 

[Rockabilly]

Good work Ben.
Cheers

 

[GeoKez]

Liking it Ben. Reminds me of that ad awhile ago '....[construction noises]........... There! Fits perfectly now.'

 

[MDK87]

You did that with a stick welder? Nice
A bit off topic but have you re-organised the battery tray area?
It looks very neat. :thumbsup:

 

[Benzo4gT]

Yeah Mo, battery is now located on the passenger side rear behind the rear seat in the cargo area. I haven't made a permanent mount as yet due to using my deep cycle kayak battery at present, I'll have to get a DIN battery

to make it legal to have inside the car. I've done the wiring though, I used welding cable for the + and have used shorter lengths of pre made earth cable and leapfrogged and bolted them to the chassis and run it to the engine bay so

I have a proper earth to the engine rather than relying completely on the chassis if that makes sense.

It's really easy to run big cables in an RVR, the sound proofing is 2" thick, so you just cut a groove through it, lay in the cables, put the carpet back and you'd never know it was there. :thumbsup:

Here's a progress pic↓

 

[4piknup]

Benzo's backyard blitz

 

[MDK87]

Awesome job. I'd be keen to do the same with mine when I get it on the road.
Where have you taken the air inlet?
Did you make some sort of ram air intake? It looks so tidy mate.

 

[Benzo4gT]

Easy as Mo, air inlet is in the front guard, made a hole where the battery used to live and put some spare door seal around it to stop it from shredding things, tacked on a bracket for the filter, used a piece of thick plumbing pipe

to reshape the washer bottle so I could get the piping past it as well as fitting a thermo fan in.

Apologies for the untidy workspace, I have a busy mind so I usually do 4 or 5 things at once

 

[MDK87]

I like it.
I made a sealed ram air intake one of my old cars, similar to this.
In my head it improved throttle response. Haha

 

[Benzo4gT]

Update: Wrapped and welded on 3" dump pipe. I painted the wrap in flat hi-temp, I wanted a black wrap, but it's twice the $ and you can't soak it in water when you put it on :huh: Paint will work as far as I'm told.

Next up will be the Ext. WG work. Stay tuned

Forgot to mention, I've cut off the internal WG shaft and welded it up! No going back now!

 

[Benzo4gT]

Update, wastegate is on, finished today, it's an ebay one, WintonM got it cheap as hell and the vband should fit other gates if I need to change it.

Interestingly enough, it gets decent reviews and has a really decent silicone diaphragm, here's hoping

edit: Forgot to mention, steampipe is measured as an inside diameter, other pipe is outside diameter, and although it looks rough, the inside is smooth, it's getting wire brushed and wrapped anyway

 

[Benzo4gT]

I did this today ↓

It's rough but it works

 

[evo-gsr]

Anymore progress on this Benny?

 

[Benzo4gT]

I haven't been on to it much lately, but I have wrapped it and completed the rest of the exh. system. Plus WB

I've changed it to auto, so all the pedals are done, shifter in, shift box wired. Auto box is not too far away either :thumbsup:

 

[VIN18M]

Love the work on the manifold, looks like it will do the job. Good idea welding that piece on too, no point making up another flange and bolting it on-just another gasket to worry about leaking!
Heat wrap might sacrifice the longevity of your manifold though, I had my old dump pipe done and when I pulled it off you could clearly see the heat had made the pipe break down and start to flake.
A lot of people do it though so it might be fine.

 

[Django]

Epic work, love how you've really utilized the space you had to work with. Love external gate setups, nice one mate.