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  1. #1
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    Twin Turbo 850 Project Update...

    Alot has been accomplished since my last update. To begin, the manifolds were completed. This wrapped up all three phases of TIG welding. Phase 1 involved welding of the log and runners to the manifold flange. Phase 2 involved test-fitting and welding of the T3 turbo flanges to the log. The final bits were completed in Phase 3 which included the welding of the wastegate flanges, the support brackets and the heat shield studs. Here's a few pics...
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    This one is of the completed manifolds...

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    These pics are of the Passenger side manifold...

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    These are of the Driver's side manifold...

    .

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    This is of the passenger side turbo mounted in the car. Fortunately, when I test fitted the turbo, everything lined up just the way we wanted it to. Unfortunately, the perfect fit was limited to the turbo itself as the wastegate flange turned out to be about 10-15 degrees off. This caused the wastegate to hit the frame rail during installation. So...this means that I will have to pull everything out and make yet another trip to the welder to have this little glitch fixed. Here's a pic of the turbo installed on that side...

    .
    These pics are of the turbo installed on the driver's side of the car. As you can see from the first pic, the exhaust manifold is in place with the heat shielding attached only on the front half of the manifold. The rear half of the shielding will be affixed after the wastegate is mounted and permanantly plumbed. The second pic is of the turbo from underneath of the car. I think the tight space speaks for itself insofar as the difficulty of making it all fit...

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    Notice that there's only 1/2" of space between the turbo and the steering linkage...

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    This pic of of the oil return lines back to the oil pan. This was taken from underneath of the car, obviously, so please forgive the poor quality/angle of the pic...

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    The final pic for this installment is of the Split Second Controller. It finally arrived on Friday and I set up a power supply and some bench test equipment to ensure it was operating properly before installing it in the car. I'm still learning how this thing works so have lots of questions for their tech support people come Monday morning...

    .
    Speaking of Monday morning, I just realized that it's pretty late and should go get some sleep. Cheers all...
    - John

    BMWCCA #288391
    '92 850iA
    '00 R1100RT


  2. #2
    545i
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    no expansion joints on the manifolds?

    great modifications. Just the curious question on the flanges for the exhaust manifolds and why no expansion joints for when it gets hot.

  3. #3
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    Member No: 8262 revhigh is an unknown quantity at this point revhigh's Avatar
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    NICE! I may need to ask you about the split second

    fuel timing computer. I'm thinking of adding the split second ARC2 on my turbo Porsche project.

    Your project TT V12 is coming together nicely. Congrats!

    I can't wait to see it soon. I'll be hosting another dyno war here towards the end of May or early June.

    C-Ya,
    Rev

  4. #4
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    Had alot of debate about that, actually...

    and basically decided to move forward without them. Seems that 1/2 the people I consulted with said it would be a problem while the other 1/2 said not to worry about it. The worry-free folks were, in my opinion, more experienced with real life applications so I followed their advice. Hope I made the right decision. Rgds...
    - John

    BMWCCA #288391
    '92 850iA
    '00 R1100RT

  5. #5
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    Thanks, John....

    Feel free to contact me offline about the Split Second Controller. I can't vouch for how well they work since I haven't actually hooked it up yet. However, it seems to have all the features I needed and a few that I didn't. Rgds...
    - John

    BMWCCA #288391
    '92 850iA
    '00 R1100RT

  6. #6
    545i
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    understood

    sometimes it is best to listen to experience. Just sad that it was divided so evenly;) Hope it turns out great for you.

  7. #7
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    Member No: 8262 revhigh is an unknown quantity at this point revhigh's Avatar
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    I wish I could make it to the 8-fest w/ you guys

    I enjoy hanging out with the East Coast 8'ers and admiring your fine rides. I have a wedding to attend that weekend so I'm out. Hopefully the next one and other local meets.

    I'm interested in the stand alone "controllers" for that Porsche I mentioned to you. I'm not a big fan of stand alone electronics from my previous experience with them on my turbo RX-7's. I can learn to like them again if that is my most cost effective and problem solving solution.

    btw-trying to setup another dyno meet in early/mid June.

    Talk to you soon.

    John


    RevHigh E39 performance parts for sale

    "By ignoring this revolution and avoiding the changes that are inevitable, you leave your future at risk."



    Just a' good ole' boyz tune

    The General's horn

    Are you ready?
    last dyno sheet more to come N/A

  8. #8
    sammy
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    Re: no expansion joints on the manifolds?

    I think that might be an issue, if the manifold can't expand it will pull on the studs and most likely break or strip the studs. Ask me how i know!

  9. #9
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    As previously mentioned, I chose not to...

    ...include them. Check archives for reasons. Would appreciate your input, though. I'm not completely against putting expansion joints in even though the install is nearly complete. Rgds...
    - John

    BMWCCA #288391
    '92 850iA
    '00 R1100RT

  10. #10
    Johnny stahl
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    Re: As previously mentioned, I chose not to...

    John I'm not sure who told you not to worry about it, if you look at how long that flange is and realize its going to mount up as one piece against an extremely hot surface whats to stop the whole flange from expanding or deforming from the extreme heat? Normally if you don't run expansion joints then the flange should be two pieces instead of one. I guess you will find out how much heat your V-12 puts out, you might be ok, but since you made these from scratch why not include expansion joints?

  11. #11
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    Actually my first time making my own manifolds....

    Can you describe to me what you mean by an expansion joint? I originally thought you meant splitting the flange - which is easy enough to do. Is this what you mean? - - Or do you mean a joint in the log??? Rgds...
    - John

    BMWCCA #288391
    '92 850iA
    '00 R1100RT

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