GTV TB: GT2560R & FMIC upgrade

[Carlo 32]

Let's start a dedicated topic about my 100year+ upgrade project.

 

In progresss:

- 305 Brembo with 24V fusee

- Eibach springs

- Bilstein/Koni

 

AND:

- Garrett GT2560R (aka GT28R)

- 70mm downpipe

- 550x180x65mm FMIC

 

Engine will stay completely standard for now, first all above has to be finished. It's equiped with a Squadra chipset, hopefully it will be driveable with this. I have a set of GTa injectors and also a set "Green- Giants" on the shelve. I am quite sure that in the end the original motormanagement has to go too.. so on the shelve is a Megasquirt motormanagement system as well.

 

Goal:

300horses... 400Nm...

No idea at the moment if this is realistic... Maybe 280hp / 360Nm is...

Edited July 28, 2015 by Carlo

[Filip 124]

Nice! I'm excited to follow this project because I can't do any mods myself now that university fees are eating up my budget!

[Carlo 32]

Today finished the main parts of the 70mm with 5" metal Cat. All together with spotwelds for now. Next... The finale welding and the mounting points!

Edited August 1, 2015 by Carlo

[Carlo 32]

The exhaust mountingpoints are also done now.. All is about ready to be TIG-ed...

 

Yesterday tailored the intercooler to the throttle piping in place. One bracket to do on this side. Next is Turbo to Intercooler piping to finish..

 

Also one airco pipe/hose has to be changed: a little different route and getting rid of the crazy shaped aluminium pipe (which is already repaired once).

Also desided to route the powersteering pressure line somewhere in the bumper to get rid of it behind the radiator: it's just to much in a to small area... So that needs a new longer hose...

[Carlo 32]

Yesterday all evening TIG-welding the downpipe and today it still fitted perfectly! Fortunately no distortion because of my "expert" welding. :-)

 

Also finished the new hose for the powersteering: now it runs inside the fiberglas bumper insert instead of the cramped area between radiator and turbo.

Edited September 11, 2015 by Carlo

[GTV-TB 315]

No distortion ..... you are an expert welder.  

[Filip 124]

More updates, come on! 

[Carlo 32]

Updates...

While test fitting the downpipe the spotwelds broke from the modified turbo Y-piece / mounting bracket (which has to be welded with nickel, because it is iron, by a specialist welding company). So position was lost and had, together with the finished downpipe, to be spotwelded in position again...

 

In the meantime I was searching for weeks for the hose connector for the compressor outlet I bought some time ago: nowhere to be found!?!... Somehow I thought maybe it was hidden in the lump aluminium I got lying around... So after a bit of monday evening labour I found it finally on the lathe! 

[GTV-TB 315]

Looking good

[Carlo 32]

Today, I started to create a bracket for the turbo support to the engine because I cut of the Y-piece from the original bracket because I had to reposition the Y-piece as a result of the bigger turbine housing. First plan was to let it reweld with nickel by a specialist welding company... but I prefer to keep things under my own control so completely made a new one which bolt to the 4 boltholes from the T25 flanche.... Almost finished..  

[kunev 131]

Did you know internal diameter of pipe 1 on intercooler side (lower part) on bellow picture?

I want to use it in my setup and hope to not be too small.

[Carlo 32]

Hi Kunev, outside diameter is 54mm, I guess wall thickness is 3 or 4mm. So internal diameter is 46mm at least I guess.

I forgot to make exact measurments last weekend! :-S

 

I tapered the inlet side so it is less restrictive.

 

It is also used on the Squadra Tuning Spider 2.8 TB. So good enough for at least 325 horses and 440Nm

Edited September 2, 2017 by Carlo

[Carlo 32]

Yes... still busy with the 100 year project...

 

Found by accident exhaust manifolds from a 166TB... I prefere these because of the much better way they connect to the cilinder head. Of course I needed to change the connection pipes for this...

 

"Fortunately" the already finished front connectionpipe didn't fit anyway (somehow?!?).  So on the possitive side I just needed to redo one extra connection pipe (to the rear cilinders).

 

Piping will be finished today and I make a start for some heat shielding between the sump and the exhaust connecting pipes and downpipe. That will prevent to some extend the unwanted heating of the sump by exhaust heat (and no need for a bigger oilcooler ). Don't want to use heat wrap because it's not that dureable and also will cause extreme temperature of the pipes itself which can cause distortion and/or cracking.

 

Also need to make new brackets for the original TB heatshields. Already made a heat shield between the turbo + downpipe elbow and the engine block.

 

 

Edited October 2, 2016 by Carlo

[Carlo 32]

Just another year went by... and... it runs!

[kunev 131]

That is a good news  . And how it feel and what is current state?

[Carlo 32]

1 hour ago, kunev said:

That is a good news  . And how it feel and what is current state?

It runs like a normal TB with a deeper exhaust sound I think.. 

 

No seats yet so only free reving so far..

All mechanical stuff is done, only interior and front bumper... And some little finishing under the bonnet, checking etc.

[blackbini 100]

Looks great, looking forward to see more

[Carlo 32]

10 hours ago, kunev said:

That is a good news  . And how it feel and what is current state?

It runs like a normal TB with a deeper exhaust sound I think.. 

 

No seats yet so only free reving so far..

All mechanical stuff is done, only interior and front bumper... And some little finishing under the bonnet, checking etc.

[Carlo 32]

Ready for the bumper to go on... ☺

[Thanos 193]

Do you think that a big FMI as this is necessary?

 

[Carlo 32]

2 minutes ago, Thanos said:

Do you think that a big FMI as this is necessary?

 

It is not realy big.. It is more that the original is realy small! 😄

 

The bigger the better (to some extend..).  This one is 180mm high.. at some point I almost decided to drop this one and go for the 230mm version.. Next common sense came back again..just in time! 🤣

 

The cooling area is twice as big now and for the boosted air the area is also twice as big to run thru. So it means there is less drag for the boosted air and it stays twice as long in the intercooler (travels slower). It means this intercooler is in effect FOUR times bigger. AND in a much better position. ☺

[Thanos 193]

I am asking because i have maybe a similar size intercooler (550x180x65) but I do not really like the idea of the long pipes...

But I ll try it out anyway.

 

Was thinking if something like a FMI as the pics I am posting would be better? Or it could also be worst... who knows..

 

 

 

 

[Carlo 32]

 

@Thanos The length of the pipes doesnt matter that much. And.. in fact the length is even less than the setup from the pictures you posted. I think they end up with more pipe length and a smaller and less efficient intercooler.

[blackbini 100]

the edges on the intercooler with red piping are not very flow efficient, this could be optimized.

[Carlo 32]

55 minutes ago, blackbini said:

the edges on the intercooler with red piping are not very flow efficient, this could be optimized.

Tha IC looks very "boxy"... not the most efficient one I guess.

 

I think the pipes are bigger diameter than what I used. I used OD 55mm (ID 52mm) stainless and ID 54mm silicone which is the same as standard.