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Phil
Administrator
 187 posts
Jan-1-1902 |
| | I don’t have any earlier pictures, but here’s the setup my friend has:
- AP1 Honda S2000
- Ebay turbo manifold + capped wastegate port
- Ebay internally wastegated turbo
- Ebay intercooler
- Modified AEM Intake (for charge piping)
First, a shot of the two KA24DE Nissan motors he has lying in his garage. The one on the right, when removed, ran on maybe 2 cylinders.
Anyways, the turbo build on his S2000 is one of the budget variety, meaning that we’re entitled to using the stupidest parts for things. Example:
Those are exhaust hanger U-bolts holding the intercooler to aluminum plumber’s tape, which is bolted to the frame rails. The plumber’s tape gives the setup a bit of flex, so the intercooler doesn’t end up being a frame member.
This picture shows the AEM Intake, which has been used as part of the charge piping. It was used because it has provisions for emissions equipment, so we didn’t have to deal with making ports for the hoses or anything of the sort.
Picture below shows the manifold in place. On the bottom is the wastegate flange, which has been welded shut.
This image shows the turbo in place. The manifold is designed for an external wastegate setup (hence the wastegate port), so the internally wastegated turbo he used presented a major problem in terms of downpipe fabrication. More on this later.
The problem with the internal wastegate turbo is that the back of it extends an extra 2-3" for space for the wastegate. This creates a problem, because it means that the downpipe can’t just make a 90* bend downwards: it has to make a more-than-90* bend, then come back, all while offsetting to the side to clear the manifold. Originally, we had planned on using 3" tubing, but clearance problems prevented this. Luckily, we had a piece of 2.25" ID steel tubing that Denis and I had practiced welding on. We hacked it up a bit and made the downpipe from that.
First though, we had to figure out how to cut the pipe. Drew had provided some $30 pipe cutting tool that, with some finessing and a lot of cursing, could be used to make angle cuts on the pipe.
Repeat cutting about 9 times, check for fitment, tack weld, recheck fitment, then weld together.
Almost completed downpipe:
Finished downpipe, mounted to turbo:
With about 4 hours left until the tuning session, we started working on the rest of the setup. Injector install was a pain, particularly because I dropped an injector onto the top of the transmission as I was getting started. Half an hour later, I extracted it with a bunch of cursing and a J-bolt. As we were getting started on the oiling system, we discovered that we had lost the stainless hose cutter. While looking for it, our deadline for completion of the car (given a 1 hour drive to the tuning center) passed. Drunk and defeated, I got a ride home and passed out.
I look funny. |
-Phil
http://www.the-phil.com
http://www.premium-salvage.com
http://www.chelxabong.com | Posted at 8:52am on Sat, Mar 10 2007 |
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| | Sucks to hear.
Car looked like fun. What kind of power did you get out of it? |
| Posted at 3:59pm on Mon, Nov 19 2007 |
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| | Holy shit. That really blows.
They ever find the shell? |
| Posted at 3:26pm on Tue, Nov 20 2007 |
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Wedge
Member
 406 posts
Nov-19-2007 |
| | That sucks.
I am glad I am not the only one on this board with a couple ka24de laying around.  |
-Alan
* > H-T | Posted at 3:48pm on Tue, Nov 20 2007 |
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Wedge
Member
406 posts
Nov-19-2007 |
| | If the SR were to take a dump, well I’d probably get another SR. But, if I had to do it all over again, well maybe.
They are just such an ugly motor though. |
-Alan
* > H-T | Posted at 4:03pm on Tue, Nov 20 2007 |
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