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-   -   mynew little rubber burner project,4wd/24v turbo/caddy (https://www.volvoforums.org.uk/showthread.php?t=61846)

foggyjames Dec 30th, 2009 10:53

Ah, the "MAP Daddy" :) We went to one of those a while back on the 740. Spot-on piece of kit.

cheers

James

powernut Jan 2nd, 2010 14:08

yearh had a few problems , as it ended up been a faulty sensor ,anyway now replaced and up at 27psi , just glad its 4wd to give the tracksion effect , also broke a gearbox mount so upratted that too along with a powerflex mount to hardern things up, had some snow fun too

http://i46.tinypic.com/5dq795.jpg
http://i48.tinypic.com/hx832p.jpg

powernut Jan 4th, 2010 18:54

heres the link guys ,(for runing standalone megqsquirt ms1/2)

just contact phil on his homepage highly recomended guy, very helpfull, with help/suport, and he will suject best ecu for ur engines setup ,
(you,ll see a caddy pic of mine on there too, 27psi on a stand alone ms2 ecu ,,,
http://www.extraefi.co.uk/
http://www.extraefi.co.uk/gallery.htm
thought this would be of use as theres loads of standalone systems out there which are pricey to buy, the kits are brand new, and assembled to a high standed, as complete with labled wireing loom, instalation cd, etc ,,,as i know this kit was setup and tunied and runs/boosts a treat , once the niggy tunieing parts were sorted out ,,,

powernut Apr 29th, 2010 21:42

ive a bad update yes another engine has failed on the crankshaft , after doing some research on the 24v engines either 2.8/ 3.2 they all have a crank problem with bearings/spun bearings , after i spoke with some companys regards this problem , they said it dose help useing upratted bearings and arp bolts , but the problem will still havin , as there unsure if its the steel of the 24v cranks or the bearings/or crank oil ways or oil pump issuises , so ive decided to call it a day , too un relieable and costly .

so whats next , ive decided to go back to oringal idea and use a mk3 12v vr6 and turbo that , they cheeper to replace, and i should be able to get 20psi from it ,, i know they dont look as good , and maybe a little down on power , but once ive re adapterd it to a turbo , verything should run smooth (fingers crossed)
first the bargin 65.00 ford galaxy engine lol (cd-v6) bought from a auto with a headgasket failure ,, (cheep and cheerfull ) bought it thursday
first the engine
http://i46.tinypic.com/2njj2qb.jpg
http://i49.tinypic.com/1z1z5ud.jpg
then stripped it/bores look good, crank looks good/ill replaced the timing chains/tensionors/giudes while its out tbh as these are own to be rattley buggars
http://i48.tinypic.com/14e9btf.jpg
http://i46.tinypic.com/v5g3tl.jpg
next went out and got some piping to make a new exhaust manifold as i carnt use thoses vr6 turbos as theres no room for my turbo
http://i45.tinypic.com/2pq2tz6.jpg
and just had time to chop a collector
http://i49.tinypic.com/vnftoi.jpg
then removed the old vr manifolds and noticed some are ovel ,so modifyed the pipes
to fit
http://i49.tinypic.com/291lv68.jpg
http://i47.tinypic.com/2sbssco.jpg
http://i48.tinypic.com/10ztm42.jpg
ill make a start on the flanges and start assembly when the engines all built in the caddy and use my 02m gearbox so i can keep it 4wd ,,

powernut Apr 29th, 2010 21:43

hi all as some know ive been have trouble with 24v engine crank failure ,(spun bearings )
as the 12vr6 turbo seems to hold up very well , im going to use a mk3 vr6 crank in to a 24v engine along with upratted conrod bearings and arp bolts and oil pump,
first did a few mock up pics
r32 crank mk4 , shiny one
mk3 vr6( oily one)
first both cranks
http://i47.tinypic.com/19eup.jpg
note im useing the 2.8 mk3 crank as it going into a mk4 2.8/not a r32 engine :laugh:
also did a few mocks up and fitted the r32 crank in the mk3 block fits a treat shame about the pistons just standing proud
http://i50.tinypic.com/xcklc2.jpg
http://i47.tinypic.com/2644d50.jpg
next checked the mk3/4 oil oils odd thing they look idenical yet the mk4 has a deeper sump :confused:
http://i45.tinypic.com/2v1xnau.jpg
also made a start on the short runner if this dosent flow nothing will
going for 2inch intake pipes x6 and 114.3mm tube lol
http://i50.tinypic.com/2gtxcat.jpg
http://i50.tinypic.com/2i1m7no.jpg

powernut Apr 29th, 2010 21:44

as most know ive rebuilt the other 24v engine and it was ready to fit , and evern thow they look nice and fill a space i decided fit the early 12v mk3 vr6 which u all might have seen eariler in the pic , since then skimed some pistons down to drop compression (save useing a head spacer )
http://i42.tinypic.com/2ajug61.jpg
then re fitted all new valves and guides
http://i42.tinypic.com/jptxr6.jpg
added the mk4 r32 crank for a stocker engine
fitted new chains and tensionors to be safe
and hd crank bearings and new oil pump/filter
arp conrod bolts
steel 14lb single flywheel and cermic 6 paddle clutch
re built the gearbox
and blasterd sprayed engine
used a few pars from the mk4 r32 engine thermostat houseing/injectors/fan belt tensionor
http://i44.tinypic.com/1zq9h8g.jpg
http://i39.tinypic.com/2mdma1s.jpg
http://i44.tinypic.com/swxmxi.jpg
http://i43.tinypic.com/33tqqh5.jpg
just hunting for another turbo unit and il then make another tig welded twin scroll manifold and a alloy short runner intake , then hopefully get it runing :thumbs_up

powernut Apr 29th, 2010 21:46

thought id knock a short runner up to find ive not enoegh room at the front
http://i40.tinypic.com/16itg6w.jpg
so that was thown in the scrap
next only thing i caould do is modify the stock intake manifold but keep the runner lengths the same
http://i40.tinypic.com/68woxf.jpg
http://i44.tinypic.com/20r9t9w.jpg
ill just finish the welding 2moz and do of wireing unit turbo arrives
well a bit for you lol
managed to weld rest of the intake and modify the rocker cover too

http://i41.tinypic.com/vrehw8.jpg

http://i42.tinypic.com/14uez53.jpg

modifyed the breather and has a better idea with wire gauze and oil splash plate , which should help in boost , what a pain to alloy as the alloy contains very small fragments of hot oil and i assume over the years its contamiated the alloy , but got there in the end

http://i42.tinypic.com/1z9mdu.jpg

fits a treat nice and air tight [:P]

http://i40.tinypic.com/ak7oya.jpg

http://i41.tinypic.com/2zg6gkz.jpg

also saved a good 5inch , so means i dont really have to change the sump , but i think ill make a shorter one

powernut Apr 29th, 2010 21:47

just a idea long as it works chuff the high boost lol
hi guys well had a bit of free time so thought id make a new coil pack mount
removed the old sensor and filled the old hole up with alloy
http://i41.tinypic.com/j95v0o.jpg
lump of 3mm alloy then driled a few holes
http://i39.tinypic.com/2jba5jt.jpg
then added a 5mm lump of rubber and bolted the coilpack up to the back plate
http://i44.tinypic.com/16atog0.jpg
http://i44.tinypic.com/jjy7gp.jpg
noticed i left a gape between the timing chain cover and the back plate , save engine heat on the coil pack and added the rubber to keep it cooler ,
injectors re wired, and all engine loom wires alterd , tempord to try a start up 2moz ,,be a tad noisey but should fire up

powernut Apr 29th, 2010 21:49

first off thought id check the intercooler pipe fits a dam treat with clearance too , think ill tig a dump valve in there, also heated the plastic vacum pipes for the brake servo and re solderd all the wires and shorternd them,

next as i have a bit more room i pulled the exhust side in around 2inch ,(saves a rattle

http://i39.tinypic.com/zo6e0i.jpg

http://i44.tinypic.com/akbm69.jpg

then new turbo arrived so thought might as well make a manifold , first tempory fit ,

you,ll notice its on a angle reason is ive no room to run a dam boost pipe , ive an idea thow lol

http://i40.tinypic.com/eqrnuv.jpg

http://i40.tinypic.com/av3952.jpg

few start pics of the turbo and manifold progress

http://i44.tinypic.com/iz6wxt.jpg

http://i42.tinypic.com/5f5jec.jpg

http://i42.tinypic.com/k0v9i.jpg

powernut Apr 29th, 2010 21:49

not too mutch but had a slight engine prob ( nothing bad ,just a stuck hydrolic tappit ) now runing on 6 pots , dosent sound too bad tbh , also added oil t piece and reducer, and made oil return 19mm bore , modifyed ht leads to suilt, redone manifold had a small blowing, had to alter external wastegate still in the way but ill mod the air intake, next is modify some boost pipes , sensors, intercooler,hoses,, ive also dropped on a pair of poly bushes which ill make some new mounts from too few pics here

http://i43.tinypic.com/2lid9ph.jpg

http://i42.tinypic.com/2vs2450.jpg

http://i44.tinypic.com/2d6ma13.jpg

http://i41.tinypic.com/2isf6mf.jpg

http://i39.tinypic.com/iw23cp.jpg

quick engine video

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