Time to go Stage II!

[Alky V6]

The hanger went through a redesign today. I figured out a way to triangulate the whole unit. I can pick up the whole engine by the hanger now.
I'll post pics tonight.

This is part of the fun I get out of this project. Figuring out a better way to get the job done.

 

[norbs]

Ya I didn;t like the design either, but was too scared to say something..

 

[Alky V6]

Ya I didn;t like the design either, but was too scared to say something..

Norbs. Never be scared to input 'constructive' criticism. The important word there is constructive.

 

[turbobitt]

Norbs. Never be scared to input 'constructive' criticism. The important word there is constructive.

I actually really liked it. Can't wait to see the new one.

Allan G.

 

[Alky V6]

Here is the new design turbo hanger. The turbo in the following pictures is mounted in a position that will be used when the engine is mounted in the car. The difference between these new pictures and the pictures I just posted previously is a heim link that will be between the hanger and the turbo. The heim link lowers the position of the turbo quite a bit.

 

[Alky V6]

New overall pics that show the position of the turbo better. This is the same location that was used with the Stage I configuration.

 

[RIFF RAFF]

LOOK'S AWESOME ! Don what will keep it from twisting to the heavy side ? piping ?

 

[Alky V6]

LOOK'S AWESOME ! Don what will keep it from twisting to the heavy side ? piping ?

What part are you talking about? The hanger or the turbo itself?

 

[RIFF RAFF]

the hanger .that turbo looks like a big heavy bitch .

 

[Alky V6]

the hanger .that turbo looks like a big heavy bitch .

The first design of the hanger that I posted did have that tendency to twist just a little. The new design is rock steady. The real secret to building a support like this is "triangulation". You will notice that this new support is a combination of two triangular pyramids separated by a small 'triangular' plate in the middle. The triangle is the strongest shape there is. The structure might as well be solid steel. That's how strong this structure is.
If you study the pictures, you will also see that I moved the attachment point at the turbo end of the structure closer to where the three rods join. This lessens the leverage that the weight of the turbo has on the end of the support to cause it to twist.

 

[RIFF RAFF]

YES I SEE . BUT THAT IS STILL A BIT OF SPACE BETWEEN YOUR CENTER SUPPORT'S AND THE TURBO [ LENGTH OF ROD'S ] I COULD SEE IT TWISTING ON A GOOD 4 FOOT DROP .

 

[Alky V6]

Here's another interesting thing about this support. Not only is it supporting the weight of a very heavy turbo, but I can take my hand, put it over the turbo end of the support and add more weight, and the support does not deflect at all!

 

[Alky V6]

YES I SEE . BUT THAT IS STILL A BIT OF SPACE BETWEEN YOUR CENTER SUPPORT'S AND THE TURBO [ LENGTH OF ROD'S ] I COULD SEE IT TWISTING ON A GOOD 4 FOOT DROP .

Before I put the turbo onto the hanger, I tested the support by holding it by the turbo mounting end and lifting the engine until the one front engine stand wheel lifted from the ground.
I did this same sort of testing with the tripod I had fabricated for the Stage I build. Just make sure you triangulate.

 

[RIFF RAFF]

Here's another interesting thing about this support. Not only is it supporting the weight of a very heavy turbo, but I can take my hand, put it over the turbo end of the support and add more weight, and the support does not deflect at all!

LAID TO REST ! not to change your train of thought ...but . are you planing something new with the suspention ?

 

[Alky V6]

LAID TO REST ! not to change your train of thought ...but . are you planing something new with the suspention ?

Out of the gate, I'm not planning on any changes. Down the road, I'm sure changes will have to come.

 

[kidglok]

How about something coming off the radiator support? Supporting the turbo from underneath somewhere?

 

[Alky V6]

How about something coming off the radiator support? Supporting the turbo from underneath somewhere?

Both those methods would also work. Even still, the use of a support(s) that makes use of triangulation will be the most effective at supporting the weight and deflecting the least.

 

[Alky V6]

The next step will be fabricating the Y pipe that will feed the turbine. I'm still waiting for a custom expansion joint to come in from SPD, so that may slow me down a bit. I plan to add the expansion joint to the driver's branch of the Y pipe.
The Stage I project showed me that there is plenty of room above the turbine housing for the exhaust plumbing. The exhaust plumbing does not have to hug the engine as tight as it did with the Stage I project. Moving the exhaust plumbing away from the front of the engine will make serviceability of components mounted to the front of the engine a little better.
First thing to do will be to decide on a new clock position for the turbine housing inlet. Looking at the turbine housing wheel straight on, the housing will be rotated clockwise slightly so that the inlet is pointing closer to a straight up position.
I'm going to use the same T4 to T6 adapter flange that I used on the Stage I project. It has an integral spool valve that I fabricated, but I'm sure I probably will not need to use it on the Stage II project. I came to a point where I wasn't using it on the Stage I project, either. The nitrous/methanol anti-lag strategy that I eventually came up with out performed the spool valve immensely.
The adapter flange w/spool valve will be used, but the T4 side of the flange will be modified to accept the larger pipe sizes that I plan on using with this new build.
Some porting out of the flange will need to be done to better match the inlet of the S510 turbo better. The feed hole in the flange was originally made to match the T4 flange of the old Stage I exhaust headers more than the T6 side of it, so the opening is a little smaller than the S510 turbine inlet. If the spool valve ends up getting in the way, it will be removed from the flange.

 

[Alky V6]

What I like about having the turbocharger hanging down off of the support on the heim link rather than having the turbo teeter on some sort of mount below the turbo is when servicing time comes it's a more convenient setup.
Say I have to remove the exhaust system in the car. As you can see, the mounting on the turbo is positioned very close to center gravity of the turbo. When the exhaust system is removed, the turbo will simply hang there in position on the heim link.
Without any mounting assembly below the turbocharger, there is plenty of room to service things on the engine from below the turbocharger. For instance, if I wanted to remove the timing cover, it can be removed in the car by working from underneath with the car on a rack, while not having to disturb the exhaust system or the turbocharger at all. I've already had to remove the timing cover in the car with the Stage I configuration in the past and it was a nice feature not having to deal with the exhaust system to perform that operation.
Having the turbo mounted with the heim link allows the turbo to move about some to account for exhaust system expansion that will occur due to exhaust heat.

There might be one issue that I might have to change the turbo support to correct. One of the legs of the support is secured at one of the timing cover bolt positions. That leg will need to be removable if I need to remove the timing cover. The old Stage I support used much longer legs that did not have the legs tied together in the middle as this current one is. With the old support I was able to remove the one bolt from the timing cover that secured the one leg of the support and slighty bend the leg out of the way so that I could remove the timing cover. With the leg being so much shorter with this new support, bending it out of the way would be too much stress on the metal of the leg. If I find I need to, it shouldn't be too much trouble to figure out a way to make that one leg removable without having to disturb the rest of the hanger. I might make that modification to the support now, while it's still convenient.

 

[Alky V6]

I have to say, I don't really like the turbo support painted gloss black. I kinda preferred the plain steel color. I'm going to try to find a blasted steel color to paint it, after I've made the one support leg removable.