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  #1  
Old 08-01-2012, 05:29 PM
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Engine Cleanup

As part of the process of installing the "test pipe", in the 107 diesel, I thought it would be a good time to get the engine cleaned up. I had to pull the turbo and manifolds so the entire side of the engine is exposed for cleaning.

The intake manifold was an absolute mess, but it cleaned up nicely.



The turbo and exhaust manifold are next.

I want to thoroughly degrease and pressure wash the engine so I needed a way to protect the ports while I do the job - this is what I came up with.





It's a piece of 3/16" angle aluminum. I'll use the old gasket and smear it with grease then cinch down the port protector to provide a water tight seal. I originally thought that the angle would provide some needed dimensional stability, but I don't think so, so I cut most of the angle off.

Attached Thumbnails
Engine Cleanup-intake.jpg   Engine Cleanup-port-protector.jpg   Engine Cleanup-port-protector2.jpg  
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  #2  
Old 08-01-2012, 06:15 PM
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Looking good
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  #3  
Old 08-01-2012, 07:38 PM
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Good time to test fit a non-trap turbo setup

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Old 08-01-2012, 08:55 PM
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Quote:
Originally Posted by sixto View Post
Good time to test fit a non-trap turbo setup
You mean something like this?

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  #5  
Old 08-01-2012, 10:00 PM
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You know what I meant

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Old 08-03-2012, 02:59 PM
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Continued with cleaning up engine components. Focusing on the exhaust section now.

Here's a before, during and after picture of the exhaust manifold. In prep for paint, I wire brushed it, then media blasted it and then painted it with VHT header paint.



I then did the down tube.



Then the turbine housing





And I fabbed up a new test pipe and painted it with VHT header paint to match.



Now when my gasket kit comes in, I'll be ready install everything.
Attached Thumbnails
Engine Cleanup-exhaust1.jpg   Engine Cleanup-downpipe.jpg   Engine Cleanup-turbine1.jpg   Engine Cleanup-outlet.jpg   Engine Cleanup-testpipe06.jpg  

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  #7  
Old 08-03-2012, 03:14 PM
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Nice!

How about Jet-Hot coating and Thermo-Tec wrap while you're in there?


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Old 08-03-2012, 10:51 PM
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I hope the paint is tough enough to stay on e the exhaust parts from the heat.

Check out these guys.
Caps Brite Hot Coatings | Powder Coatings, Ceramic Coatings, Cermakrome, And More

I have seen their stuff and it looks good, they aren`t new kids on the block, they have been doing this for over 20 years.



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Old 08-03-2012, 10:55 PM
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How is this for shinny. couldn`t edit and post this in the above post.

Charlie
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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works
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  #10  
Old 08-03-2012, 11:57 PM
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Quote:
Originally Posted by charmalu View Post
I hope the paint is tough enough to stay on e the exhaust parts from the heat.
I'm hoping the same thing.

I tried to find some power coat material that would work for exhausts. Obviously there are places that will do it commercially, but I was hoping to find some DIY stuff. No much luck.

The various forums show widely different experiences with the high-temp exhaust paint. Some report good results and others show that it flakes off almost right away. True for all brands.

I elected to try the VHT Flameproof coating which is supposedly good up to 2000 degrees F. If it works, great, and if not, well I tried. On the exhaust manifold I really tried to prep the surface well by wire brushing, media blasting, washing and degreasing. Same for the turbine housing. The down tube just wire brushing.

I guess I'll know soon enough.
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  #11  
Old 08-04-2012, 01:16 AM
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The test pipe looks great. Did you cut the flanges off the trap ox to use on your pipe or did you make new ones?
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Old 08-04-2012, 01:56 AM
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did you just spray the stuff on and let it dry, or did you follow their extensive instructions?

most high temp paint has a baking in procedure to get best results...
hot rod magazine did a writeup on it... but it involved heating the pipes to 450 for 90 minutes or some such... then cooling slowly, then heating to 450 for 30 minutes and cooling slowly...
I think it was VHT high temp metal flake... it's been a decade or so since I read it though...
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Old 08-04-2012, 03:19 AM
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I recently used high temperature paint on a set of calipers - waste of time. Due to "other problems" I didn't actually go any where with them - zero miles driven - but they were fitted to the car. Within six months they had rust spots showing through.

I degreased, cleaned, shotblasted, coated and cooked the buggers. No hope in this climate!
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  #14  
Old 08-04-2012, 08:13 AM
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Quote:
Originally Posted by Tmadia View Post
The test pipe looks great. Did you cut the flanges off the trap ox to use on your pipe or did you make new ones?
Cut the flanges off the trap cat. The pipe is 180 degree 3" radius mandrel bent 1-7/8 and a 2" two-into-one piece that provided the entry into the turbo flange as well as sleeves for the other joints. Got the exhaust pipe pieces at a local dune buggy shop.
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  #15  
Old 08-04-2012, 11:47 AM
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Quote:
Originally Posted by mach4 View Post
Quote:
Originally Posted by Tmadia View Post
The test pipe looks great. Did you cut the flanges off the trap ox to use on your pipe or did you make new ones?
Cut the flanges off the trap cat. The pipe is 180 degree 3" radius mandrel bent 1-7/8 and a 2" two-into-one piece that provided the entry into the turbo flange as well as sleeves for the other joints. Got the exhaust pipe pieces at a local dune buggy shop.
Here is mach4's fabrication thread....

http://www.peachparts.com/shopforum/diesel-discussion/321831-cali-617-test-pipe.html


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