Eric's '90 80QT: rustic bits

[elaw]

Ha! I just saw your second post while writing this. Well I'll toss it out anyway...

I really don't know what I can say beyond what I wrote there. It feels like this turbo makes a bit more power for a given amount of boost than the stock one, but it's not a "night and day" difference. I've only had it up to 15 PSI and at that level I'll say it seems to make *about* the same power as the old K24 at 20 PSI. I think the difference might be greater once I get to 20 PSI (that's if I ever again get to drive on a road that's not snowy or icy) since the old turbo's compressor was way out of its efficient range at that amount of boost, and this one should be better.

One other thing I failed to mention is I switched wastegates. With the old setup, which was all stock AAN stuff except with a 1.8 bar WG spring, I could never get more boost than the WG spring setting at 7000 RPM. I think the pressure in the exhaust manifold was basically blowing the wastegate valve open.

I'd heard a rumor that 20v and 20V wastegates are different, and that rumor is 100% true. The valve in the AAN WG is a *lot* larger than in the 20v wastegate. And thus it's more prone to blow open since force on the valve is the PSI in the manifold times the valve's surface area, so more surface area = more force.

As luck would have it, I had a 20v WG sitting around so I threw that one on there. Combined with the new K24's turbine housing that flows better, it now has no problem making lots of boost right to redline.

[elaw]

Hey just a little more on the wastegate-size difference...

I just went out to the garage and measured both and took a couple of photos. The opening just inside the end on the "business end" of the valve on the 20v measures 29.8mm diameter, and on the 20V WG it's 33.8mm. So about a 29% increase in area.

Here's a photo of the two, 20V is on the right:

[my2000apb DrBeastCar]

also the ID of the outlet to DP is smaller on a 20v vs 20v

[elaw]

Ah... I guess that would make sense. The two wastegates I swapped both had the accordion pipes on them so I didn't notice.

The one other thing I failed to mention... and this is really weird... but the car actually idles better! I have no idea why, the only thing I can think of is the flow in the exhaust runners is better matched so maybe there's less AFR difference between cylinders? Or maybe it's a reversion thing... who knows. But it definitely seems to run just a tiny bit more smoothly.

[my2000apb DrBeastCar]

its just happy to be upgraded

[IdahoDoug]

Man did I pick the PERFECT day to stumble across and read this entire thread! Perfect because I finished reading right when it's up and running. Nice!

[elaw]

So I've got another question for those of you who have used -AN hoses to feed oil to their turbos... take a look at this:

I used a 30-degree fitting on the end of the hose and it fits pretty well. But it seems like a lot of the major manufacturers like Aeroquip don't have 30-degree fittings, I'd have to choose between straight or 45-degree. Can anyone tell me which would be the better choice?

[pkw]

what is wrong with what is there?

[elaw]

Well... I'm not sure there's anything wrong. But the hose and fittings are no-name stuff from a cheap supplier, and I just don't have much confidence in them. The construction seems really lightweight (as in, weak), moving parts like swivels don't move smoothly, etc. And considering the consequences of that line failing could be a ruined engine and/or turbo and/or a fire, I'm thinking I'd like something of a little higher quality.

[savagerocco]

Brent,

Whose hose and fittings do you use?

I did decide to go with regular PTFE rather than hard line, but the stuff I got seems pretty cheesy. Given the criticalness (is that a word?) of the line, I'm thinking I might redo it with better stuff.

Sorry, just saw this.... I use stainless line with teflon liners, both feed and drain. little harder to make up on the drain, cause I have them crimped but haven't had one fail yet.

[elaw]

Yeah but what brand/supplier? It looks to me like Aeroquip is about the best... do you agree?

[savagerocco]

I just go to the local hydrailic hose builder Evco. They have steel fittings, I'd say parker or gates are the main suppliers. Also, I just tapped the hole on the oil filter housing and installed a pipe thread to -4an fitting there and went right to the line, and same on turbo housing, tapped hole and installed line.

[savagerocco]

These are all the pics I could find of my lines for now.

[my2000apb DrBeastCar]

earl's makes 30's

[Hybrid_Hatch]

having used this turbo, i think you need to get tuning with it, what injectors are you running? SEVERAL members on this forum rode or drove my car with the volvo turbo, and all of those guys have also had stock k24 20vt cars, and know the difference. Any of them could tell you that there certainly was a "night and day" difference with the volvo turbo.

[mrmotorhead13]

If you're making them up yourself, use Earls, Aeroquip, or Fragola. Whatever you do don't use Russell, they break. I've probably made upwards of 500 lines when I was working for the race prep shop and we tossed anything with Russell fittings and made new lines, and I've seen them break personally. Couple other hints, don't let the SS lines hit anything (they will rub through), and support them well on long runs (particularly if using aluminum fittings). If they're not supported they will eventually fatigue and break.

[elaw]

These are all the pics I could find of my lines for now.

Man, what's your budget for red powdercoating?

Seriously, thanks, that definitely helps. I see you're using a straight fitting at the engine end of the feed line.

I also sometimes forget that there are adapters that can be used to change the angle if necessary.

[elaw]

having used this turbo, i think you need to get tuning with it, what injectors are you running? SEVERAL members on this forum rode or drove my car with the volvo turbo, and all of those guys have also had stock k24 20vt cars, and know the difference. Any of them could tell you that there certainly was a "night and day" difference with the volvo turbo.

Well, I know a lot of people like to use huge injectors and the ones I'm running are only 33 lb. But my AFRs are fine (13.0-13.5 at 15 PSI boost, a little richer at higher boost) and haven't seen the duty cycle go above 85% yet. Although I realize it's close to where I probably should be looking into something larger.

[elaw]

If they're not supported they will eventually fatigue and break.

That's my biggest worry. I know the line is fine now... but I don't want it to fail months or years from now when it's been long forgotten.

I like the selection of Earl's stuff that's available, but I've read on the 'net where some people think their quality has gone downhill. You've had good luck with them?

I'm torn between using aluminum and steel fittings. Steel of course is stronger, but I'm concerned about dissimilar-metal corrosion. With aluminum of course it's the opposite. I think some companies make SS fittings but they're insanely expensive.

[vagrant_mugen]

ive had issues assembling aeroquip fittings b4. ruined x2 ends before i gave up
on that brand.

i use only Earls now, there well made and easy to put together.
get them from summit.

[mrmotorhead13]

Earls were pretty much all we used at the race shop, occasionally a few Aeroquip (they make a few odd things no one else does), and Fragolas when Earls was out of stock on something we needed right away. I've yet to see a properly assembled Earls fitting have an issue.

This was the place I worked at... lots and lots of SS lines.

[elaw]

Hmmm... that looks a little different from my garage. I'm jealous!

I did decide to go with Earl's stuff. PTFE hose and SS fittings. It's expensive, but cheaper than a new engine or turbocharger.

I bought the stuff from these guys: http://www.anplumbing.com/... they've actually got slightly better prices than Summit, and their website is way better organized.

[mrmotorhead13]

Ya it's quite a bit different than my garage too... but every time I miss working there I just picture what a douche the owner is and I feel better. Or I look at my last paycheck and see the extra 30-40% I made. Then I feel much better.

[elaw]

Moving right along (pun intended!)...

I've had my share of bad ideas on this project, and here's another one!

One thing I've been eyeing for my car for a while is an airbox with a larger filter for more airflow. And I couldn't help but notice the ABY S2 and RS2 use airboxes that have some similarity to the one on a B4 90, in particular that they use a larger filter element. So I thought to myself, "self, why not adapt a B4 90 airbox?".

Here's the executive summary: that airbox and the AAN engine don't play nice together.

When I installed just the bottom half, it looks somewhat promising:

The housing overhangs the turbo exhaust housing in a way that would make a lot of heat shielding mandatory. And it comes close to the compressor housing (maybe 10mm?) but it does clear.

Then I put the cover on and saw this:

Yes, that's the wastegate *touching* the housing. That's pretty much a deal-killer for me... I don't think I'm ambitious enough to make the major mods to the housing necessary to fix that issue.

As it that wasn't enough, I threw on the hose that goes to the MAF sensor to see how much room there was between it and the housing to accommodate the sensor:

The amount of room is exactly... zero. Oops.

So... does anyone have an ABY S2 airbox they want to sell cheap? I'm not even going to ask about an RS2 one, at least not until I hit the lottery.

[my2000apb DrBeastCar]

aby and cheap hah