Intercooler Project for a 617 - Page 2 - PeachParts Mercedes-Benz Forum

vstech · #16 03-10-2011, 08:20 AM

Quote:

Originally Posted by Army

Good one - I also thought perhaps he couldn't afford those extra horses after all...?

yeah. my daddy used to tell me the joke about how to get the piano up the stairs...
hook a rope to the cat.
I'd ask how the cat would help with the 1000lb piano... he would say use a biiiiggg whip!

daw_two · #17 03-10-2011, 09:45 AM

you were looking for a turbo. I happen to have an extra one off of a 2001 Dodge Ram 2500 Cummins, of course.

JiveTurkey · #18 03-10-2011, 09:49 PM

Just a quick update on this project.
- I've decided to bite the bullett and fabricate an exhaust manifold from schedule 40 weld-els. Anyone know a good source for 'em?
-keen students of obviousness will note my new turbo arrived without any kind of wastegate so I'm going with an external one. Any reccomendations on size or brand of external wastegate? Should I incorporate a little muffler for it? I don't feel like integrating it into the main exhaust.
-im going to adapt SS braided lines for oil supply and drain of the turbo.
-im going to have to ditch the stock intake and filter but I'm going to make sure my source of air is nice and cold.
-intercooler plumbing plans are complete and finalization will depend on how I shape my exhaust manifold which determines the final location of the turbo.
-undecided on wether or not I can keep the stock intake manifold. Any suggestions on what I could fabricate one from?
-EGT probe installation will be easy since I'm making the exhaust manifold my self.
-i have a good manual boost controller to aid in tuning my boost/wastegate situation.

Oh MAN I'm excited for this. Now if only it weren't for that damned uniflow head...

panZZer · #19 03-14-2011, 04:38 PM

Greetings -- Turkey, You did NOT fall for a bogus chinese Holset KNOCKOFF
did you?

panZZer · #20 03-14-2011, 04:43 PM

Looking at the compressor casting it looks like you did, I would open a dispute NOW with ebay, and then start compiling the case--I think I caught this in time for you, I dont like to give you the bad news like this but you better take care of it--I know what a real holset looks like and what a chinese knockoff looks like, this grainy casting is NOT a holset piece!

panZZer · #21 03-14-2011, 04:51 PM

http://www.myholsetturbo.com/images/holsetcounterfeitprevention.pdf

http://www.dieseltruckresource.com/dev/archive/fake-holset-turbos-t242936.html

http://www.dsmtuners.com/forums/newbie-forum/306635-counterfeit-holset-turbos.html

http://www.competitiondiesel.com/forums/archive/index.php/t-28051.html

JiveTurkey · #22 03-19-2011, 08:47 PM

Found a source for weld-els today! Local hardware store, lots of shapes and sizes. Anyone know the inner diameter size pipe ill need offhand to make the individual runners from? I haven't been able to find the specs on the exhaust port size in my FSM. I also need to find a 3 inch downpipe, and some AN fittings and SS hoses for the oil line adaptation.
I've decided to mount the intercooler horizontally inside the front bumper with a downward scoop to grap some nice cool air for it.

Question (and probably a stupid one...) Can I loosen the clamp in the center of the turbo and change the orientation of the compressor outlet port and turbine inlet port? I'm betting you can't but I haven't been able to find any info on it from any of my turbo books.

Also, from closely scruitinizing the holset I have and the photos on the reference material linked mine looks either totally legit or if its a fake its the most well crafted fake I've ever seen. Like one of those fake rolex's that work perfectly fine forever that are made from stainless steel instead of gold. Ill start posting pics as soon as I begin the fabrication.

MTUpower · #23 03-20-2011, 01:08 PM

Why do you think a "M" pump will give more fuel than a MW? What or who will make the internal changes to either pump that will give more fuel? Why did you choose the HX30? Larger turbo's give higher boost at higher RPM- but of course the down side is that it will have more turbo lag- which means 1) more smoke at low end 2) more lag at low end- but most likely 3) Both. Are you willing to live with that- and if not how do you plan to remedy that? The stock turbo choices are quite fine with most of the modifications that are able to be done with the do it yourself changes on both the M and the MW pumps. In order to get more than about 150 HP you'll need to send your pump to someone to install different parts- and even then you will still get the issues of 1, 2 and 3 with this turbo as a daily driver.

JiveTurkey · #24 03-21-2011, 01:45 AM

I chose the hx-30 based on the compressor info I was able to find. The AR size and compressor size seemed right with the 617. I wasn't able to find a turbine map but that's not very suprising. I'm actually quite excited to see how well it works in this application.

On the subject of smoke...
Most people are concerned with the levels of visible smoke their diesels make, not so in eastern Tennessee. Here, one should be concerned if their diesel doesn't produce 'enough' smoke. Phrase taken from the local lexicon, "I bet thatt'l blow some smoke!" (Said with eager interest.) So no, I won't be greatly concerned with the levels of smoke.

plus I have other Mercs to drive around in when I don't feel like smoking (2 114's and a w203)

As for my inji pump I'm still at a crossroads on what to do. I like the idea of sending out a pump to have 7mm elements installed and bench flowed with the alda (aneriod compensator) and rack limiter removed and the maximum engine speed set around 4900 (motor is in brilliant shape *knocks on wood*) but I don't like the cost. A Myna pump also seems like a good option at this point again with Cost being the limiting factor.

Essentially I want this car to be able to be comfortably driven on the road while also able to take a couple pulls on the drag strip in Bristol this summer.

Anyone have any wastegate reccomendations?
Anyone have the inner diameter size of for the Weld-El pipe I'm buying to make the runners?
Anyone know where I can find a nice fat 3 inch down pipe?

Codifex Maximus · #25 03-21-2011, 02:47 AM

Seems to me that if you have the same amount of fuel going into the cylinders yet a denser cooler greater volume of air, wouldn't you make alot LESS smoke?

tbomachines · #26 03-21-2011, 09:55 AM

Quote:

Originally Posted by Codifex Maximus

Seems to me that if you have the same amount of fuel going into the cylinders yet a denser cooler greater volume of air, wouldn't you make alot LESS smoke?

The other post was referring to before the turbo spools up, there will not be as much air being pumped into the engine to satisfy the fuel supply. It can be worked out with clever tuning but these IPs are not really capable of being tuned on the fly like that, you have to know your setup (read: turbo map) and engine specs before giong and grinding DVs and installing pump elements and all that. Personally, I don't see where OP is going with all this but hey, whatever floats your boat - its an interesting project.

Codifex Maximus · #27 03-25-2011, 05:30 AM

Quote:

Originally Posted by tbomachines

The other post was referring to before the turbo spools up, there will not be as much air being pumped into the engine to satisfy the fuel supply. It can be worked out with clever tuning but these IPs are not really capable of being tuned on the fly like that, you have to know your setup (read: turbo map) and engine specs before giong and grinding DVs and installing pump elements and all that. Personally, I don't see where OP is going with all this but hey, whatever floats your boat - its an interesting project.

I see where you're going with this. Until the turbo spools up, the engine is essentially normally aspirated. And, with the added ducting and intercooling elements, the engine will have to work harder to pull in the air while attempting to burn a fuel measure calculated on the old setup. Hence, probably smoke until turbo spool.

With my 300D, I usually work the gear selector (automatic) manually to keep the RPMs in the 2000 to 2500 RPM range so I get good turbo boost. The car seems to struggle, probably due to mal adjusted trans shift vaccum, if I don't manually control the RPMs. It's a workaround until I get the vacuum system debugged.

Looking forward to the final product on Jive Turkey's project.

JiveTurkey · #28 04-10-2011, 06:55 PM

Update time:

Pulled the injection pump today. I pussed out and pulled the oil filter housing to make it easier. The IP is going to be rebuilt and tuned by a source reccomended by our very own Phil from Fastlane. They're going to tune it for about 20-30 percent more fuel. Its being done for $965.

I plan on reinstalling the tweaked IP and running it with the stock system for a couple days to get a feel for the IP before starting work on the custom exhaust manifold made from Weld-Els. I also have to replace an unhealthy sounding center support bearing for the driveline too. Everything is coming along well.

I also had to rebuild the little vee twin engine in the ol' Kawasaki Mule 3010 because it blew its head gaskets simultaneously. But thats done now.

Photos From Today.