103 Turbo Manifold Adaptors! - PeachParts Mercedes-Benz Forum

duxthe1 · #1 03-16-2011, 10:52 PM

Instead of continuing to hijack another member's thread.... Here's the 603 turbo manifold to 103 cylinder head adaptor set I've been working on.

The premis is that the 103 and 603 share many common basic measurements the most important of which is bore spacing. Since they share a common bore spacing it turns out that the exhaust ports are also the same distance apart. This allows the ports to match up between the 103 head and 603 manifold.... half way there. I quick inspection though reveals that the bolt holes in the 603 manifold don't line up with the holes in the 103 head. Thus I present my fellow enthusiasts with my bolt on adaptor set.

The first flange bolts to the 103 cyl head. It has a second bolt pattern that mounts the 2nd flange. The second flange bolts to the first and is drilled for the 603 pattern. Both flanges are waterjet cut 1/2 inch mild steel. They bolt together with counter-sunk allen head bolts. The need to stack two pieces arises from the fact that the bolt holes interfere with one another enough that a single flange wont get it done.

In the pics I obviously have the early manifold mounted for mock-up purposes. The call is in with the local breaker to procure the nicer late style manifold. Still to be done.... procure studs for use in the outer flange. I plan to TIG each stud from the back side for better holding stregnth. I also plan to TIG a few small studs to the top of the outer flange to mount a heat shield to help from cooking the plug wire ends.

Joreto · #2 03-17-2011, 04:53 AM

Great job on the adaptors

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duxthe1 · #3 03-17-2011, 10:06 PM

Thanks, Joreto.

I got the only late style manifold available locally today. It cleaned up nice in the sand blast cabinet but there is a crack in it. I've got a decent TIG in the shop but I'm not exactly a professional welder. I will definately get some experienced opinions before I try to weld it up. Luckily I'm not in a big rush. I still have to pick out a turbo before I can even fab any lines or brackets.

Here are a couple of pics with the late style manifold mocked up.

ps2cho · #4 03-18-2011, 10:46 PM

What is the "late" style manifold? Do you know what years it came from?

duxthe1 · #5 03-18-2011, 10:59 PM

The "late style" is from the 140 chassis cars... 300SD, 350SD 92-95 if I recall correctly.

osama · #6 03-19-2011, 07:19 AM

i had a very similar crack on both my twin turbo manifolds, and they did not effect the performance much but its better to weld them to prevent further damage.

very nice job. thnx for sharing

tbomachines · #7 03-20-2011, 04:03 PM

Nice job! Very clean

duxthe1 · #8 03-21-2011, 12:45 AM

Thanks for the compliments. I worked on welding up the manifold today. Prep for welding turned up a few more cracks.

I managed to get a pretty good weld over the worst crack using a nickel stick rod with the flux knocked off. In my haste to light the propane torch to post heat the weld, I dropped the TIG torch on the floor breaking my only gas lens.

Spent the rest of the day in the workshop getting the gold dredge prepped for the upcoming season.

duxthe1 · #9 03-22-2011, 12:25 AM

I finished welding the manifold today. Turns out it's not actually cast iron. It's an alloy called ni-resist and it has a lot more nickel than regular cast iron. It's not magnetic! (FWIW the shortie part of the manifold is magnetic and I assume a more standard cast iron.) I was floored when a magnet didn't stick. The nickel filler rod stuck to it pretty well though. I used the tig torch on the outer welds but I used a fluxed rod in the stick mode to reach inside and get some penetration across the inside of the worst part of the crack. You can see a bit of it through the egr hole in the close up pic.

duxthe1 · #10 05-14-2011, 01:19 AM

Thought I'd post a few pics of the progress. I've got a good used turbo. It's a .42/.48 garrett from a 350SDL. It's pretty small for a 3L but I really want low end torque from this build. I expect it to spool at a very low RPM and full well expect it to choke before it hits the current redline. In fact I'm planning to lower my redline about 1000 RPM. When I had the turbo disassembled, I ported the wastegate opening and polished the entry of the turbine volute. I also beveled the turbine outlet up to the edge of the turbine blades. Depending on what RPM it actually chokes at I may go back in and push that bevel further towards the turbine blades.

With a turbo on the mock up engine I made a new wastegate bracket and reshaped the control rod. I also bent an oil feed line from a Cali. 617 part. I had to weld a new banjo onto the line. Stock the line uses a 19mm banjo and the oil filter adaptor on the 103 uses a 17mm banjo. I also welded up a drain line. In the pic it's a solid piece but I plan to cut it about 2 inches from the oil pan and use a hose to attach the two parts to give it enough flex to manage thermal expansion. Astute gearheads will note that I am draining into the dipstick hole in the 4-matic pan, deleting the dipstick.

duxthe1 · #11 05-29-2011, 10:40 PM

A few more pics of progress.

First is the CIS airhorn adaptor "hat". Welded it out of aluminum and it uses the original airbox seal. I haven't fabricated a hold down for it. The cleanest method would be to weld 2 studs into the airhorn bump stop bar and hold it with 2 nuts on top. I dont think I want to drill it before I have the complete kit installed. The installed legnth of the cross piece will dictate where the hat is "clocked" at exactly.

Second pic is the hat and cross pipe mocked up in the car. Third pic is the setup installed on the mockup engine.

duxthe1 · #12 06-18-2011, 09:42 PM

Got a few more pics for you guys. I found a nice blow off valve in the junkyard. It's a mitsubishi part off of a Plymouth Laser. I grabbed the valve and it's flange. I've got it now welded onto the boost charge cross over pipe just before the "hat".

Other work recently done in preperation for the turbo was a replacement of the injector nozzles and seals. I also replaced the nozzle holder seals but noted mine were still in good shape but new is better I guess. For the scant cost it was worth it to ensure they don't give boost leakage problems down the road. My old nozzles had been getting real iffy as of late, these new ones have it running really well. Additionally I've recently ordered in a set of T-bolt clamps for my boost hoses, as well as a 3" V band exhaust adaptor set. I think I'm just gonna have my exhaust guy handle the downpipe. I'd rather pay him to bend a nice piece of 3" rather than trying to cut and weld all of the angles to get it from the "V" band down to the catalyst.

Very little left to do before the install. I've got to fabricate a breather system for the crankcase vapors. I'm still needing some parts from a donor D or TD. Anybody got a parts 124 D? I need the airbox, heatshield partition and turbo inlet pipe. The inlet pipe has a connection for the crankcase vent and I'd like to have that part in hand before fabbing the line.

DieselPaul · #13 06-18-2011, 11:04 PM

I've got a heatshield, its beat up, but its all there. I may also have the turbo boot.

duxthe1 · #14 07-11-2011, 01:44 AM

Update on the wagon.... It got a new radiator recently. Was figuring on replacing it soon after the turbo but a broken neck stepped up the schedule a bit. Went with the Behr radiator, and installed a Behr fan clutch as well. Not entirely pleased with the fan clutch's performance at lower speeds but once revved past 3000RPM it really howls and cools things off quickly. I can't complain b/c I got an obscene deal on the new parts.

In the meantime, I've sourced an OE turbodiesel air intake system and it should be shipped in this week. I've also fabricated a downpipe from a large 220Ch. catalyst. I first cut a flange to mount to the turbo's outlet. I then welded the catalyst to it. Next I cut the rear of the catalyst off and welded on a 3" flange adaptor. I finished it by welding in an O2 sensor bung just past the inlet of the downpipe. It all tucks up tight against the engine. I'm praying it will all fit and clear the firewall. I measured as carefully as I could with the existing manifolds and pipes still in the way.

duxthe1 · #15 07-13-2011, 11:06 PM

Waiting for the intake parts to come in, I pulled everything off of the mock up engine. Still a few bits and pieces to get in otherwise but I'm planning to install everything on the Sunday following the coming one.

I spent some time working under a 4-M wagon today. I studied the opening throught the firewall for the exhaust. I'm feeling pretty good that my catalyst / downpipe is gonna clear everything.