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  #1  
Old 08-21-2008, 08:56 PM
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Manifold Issues

Or else you get cold slugs like this that leak
Stage 3 underside of manifold

I also found a hairline crack in the TB adapter that will also be fixed tomorrow.

I finally had a few moments to work on it. Hope to have the manifold and TB adapter powdercoated again this week and re-installed by next weekend. Then I can begin to datalog and tune the system to way it should have been running for the last two years.

Tom
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  #2  
Old 08-21-2008, 09:48 PM
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Re: Remember, Pre-heat your aluminum.

What is that!? It looks so mean!!! Why is it so ANGRY!!!
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  #3  
Old 08-22-2008, 02:32 AM
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Re: Remember, Pre-heat your aluminum.

holy crap! is that the infamous vacuum leak? Does that mean its going back on!? Will the kit no longer be for sale?!
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Rebuilt P/S pump info... http://www.subaru-svx.net/forum/showthread.php?t=50918

If your car wont start info... http://www.subaru-svx.net/forum/show...ighlight=click
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  #4  
Old 08-22-2008, 07:06 AM
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Re: Remember, Pre-heat your aluminum.

How did you find it? Sheer luck or were you inspecting the pieces...
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  #5  
Old 08-22-2008, 08:25 AM
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Re: Remember, Pre-heat your aluminum.

it was buried under copious amount of powder-coating. I made a block-off plate for the blower flange and made sure everything else was sealed. Filled the manifold w/ water... It was seeping from this crease.

So at this point, I plan to fix this and the crack on the TB adaptor. Re-install the system and data-log and tune the car properly (you know... on a dyno). Hopefully this will net some better gains and reliability so it may be possible for me to sell the system so I can move on to my own turbo kit.

Bobby, just a little cliff-note. Regardless of Mike's claims that you have "cheap Chinese bearings" you have ACL bearings in you engine right now... So don't fret.

But yes, it will be going back on, and if I feel it right, I may drop a 75 shot of nitrous ontop of it to get some nice drag runs

Tom
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  #6  
Old 08-22-2008, 08:16 PM
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Re: Remember, Pre-heat your aluminum.

mmmmmmmm....... Nitrous..........
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  #7  
Old 09-20-2008, 06:01 PM
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Re: Remember, Pre-heat your aluminum.

Well after tooling around with it for a couple weeks... The boost leak has been sealed after I fixed the manifold. Still had symptoms of a vacuum leak After several hours of trying to find it... Spotted.

I was using a can of carb/choke cleaner to try and isolate any problem areas. Breezed it by the by-pass valve and got a reaction. Figuring it was simply the by-pass valve seal I began once again... disassembling the intake. As I was removing the bypass I noticed a slight spot of light comming through where it should not have been. Waved my hand over the seam to seem my shadow moving... GREAT!!! Yet another crack. The seam that is right next to the by-pass valve was cracked. Considering the welds were all external they had to be ground down for a mating surface of the by-pass valve. LAN must have gone a little too deep and left literally less than a credit-card's thickness of material... no shock that it cracked after some heat cycles. I have some 1/4" 6071 plate all cut to size and I have cut the whole side plate off the TB adapter. Bringing it back to my house tonight in hopes of having it welded on tomorrow... Fingers crossed this is the last issue I have to fix on this kit

Tom
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  #8  
Old 09-20-2008, 06:07 PM
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Re: Remember, Pre-heat your aluminum.

tom , pics soon ?
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  #9  
Old 09-20-2008, 06:08 PM
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Re: Remember, Pre-heat your aluminum.

of?? I can take pics of the side of the TB that I cut off... Didn't take pics of the crack


Tom
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  #10  
Old 09-20-2008, 06:10 PM
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Re: Remember, Pre-heat your aluminum.

of your turbo set-up i'd like to see hows going on!
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  #11  
Old 09-20-2008, 06:12 PM
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Re: Remember, Pre-heat your aluminum.

no this is the stage 3 kit I have had for the past 2 years... I have simply lost the concept that the hardware is good and have been working at fixing it lately. Until I sell this kit I do not see myself turboing my car.

Tom
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  #12  
Old 09-21-2008, 06:25 AM
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Re: Remember, Pre-heat your aluminum.

i cant view the pic
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  #13  
Old 09-21-2008, 07:14 AM
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Re: Remember, Pre-heat your aluminum.

Quote:
Originally Posted by subbieatnz View Post
i cant view the pic
Yeah we are having issues with our website right now... It is being looked into

Tom
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  #14  
Old 09-21-2008, 10:19 AM
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Re: Remember, Pre-heat your aluminum.





Tom
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  #15  
Old 09-21-2008, 09:51 PM
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Re: Remember, Pre-heat your aluminum.

OK spent all night in the garage getting this TB adapter fixed... I will try and take pics tomorrow but I changed a couple things.

1. I had cut the entire side off of the TB adaptor to replace it with a thicker gauge aluminum. That has been welded on and looks perfect.

2. I never was happy with the mating flange for the blower because it was all warped. So I cut another piece of 1/4" 6071 and welded a nice flat mating surface on. Tomorrow I will be cutting the opening for the blower inlet.

I chose to cut the hole after it was welded to avoid the kind of warping that had happened before. AL takes A LOT of heat to weld so pull and warp is something you need to think about before ever striking an arc. I have 100% confidence in the TB now that I have stripped all the powder coating and paint off of it and inspected all of the welds... I have found a few more pinholes in the welds that had not penetrated and did not cause any issues but with time likely would have. So after I patched up everything it is ready for the blower and bypass valve cuts. Tomorrow I should be able to get everything buttoned up and have the car running well... Fingers crossed

Tom
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