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The 90

PostPosted: Thu Aug 08, 2019 9:46 pm
by Afterthought
I went with straight runners for this one . It’s nearly done but I need to decide on throttle body and finish the inlet .
For the throttle body I would like to use something in the ballpark of 70mm or 2.75”.
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Now my hold up, on the inlet I need a 2.75” ID 90 degree ell in a fairly tight radius . Never mind the radius I can’t find any aluminum Ells at all, besides intake charge piping which is too thin for my manifold .
This is about the only thing I think could work,
And it’s maybe even tighter than what I would want . The description says 1.5mm thickness but If it’s the same as the one in the picture that can’t be right . https://express.google.com/u/0/product/ ... KUEALw_wcB



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Re: The 90

PostPosted: Thu Aug 08, 2019 9:57 pm
by DE80q
Look up the part# through vibrant. When I did the cast tight 90's on my intercooler, I think it was more than 4mm wall thickness.

Re: The 90

PostPosted: Thu Aug 08, 2019 11:18 pm
by Afterthought
DE80q wrote:Look up the part# through vibrant. When I did the cast tight 90's on my intercooler, I think it was more than 4mm wall thickness.

I couldn’t find it on their website but that would make a lot more sense

The 90

PostPosted: Thu Aug 08, 2019 11:19 pm
by Afterthought
DE80q wrote:Look up the part# through vibrant. When I did the cast tight 90's on my intercooler, I think it was more than 4mm wall thickness.

I couldn’t find that dimension listed on their website but that would make a lot more sense

Re: The 90

PostPosted: Thu Aug 08, 2019 11:33 pm
by DE80q
I found one made by another company listing ID 2.375" OD 2.750". So that would be a .1875 wall. Something to take into consideration. You might also try to find a "donut", you can find them on a lot of fabrication websites.

Re: The 90

PostPosted: Fri Aug 09, 2019 12:35 am
by Afterthought
Yeah I will have to keep searching around I guess.
Another thing I should consider is if I can run the slimmest possible throttle body facing straight forward and run a tight radius silicone elbow out of it, because silicone ones are all over.

Re: The 90

PostPosted: Fri Aug 09, 2019 12:46 am
by DE80q
When I was doing my intercooler, the tightest radius I could find was the cast alum. ones. Even at that, I had to chop them down to get the radius as close as I could to clear the fog lights.

The 90

PostPosted: Fri Aug 09, 2019 4:39 am
by Afterthought
Ok yeah I looked at it again. So here’s how much space I have to work with . I should be able to do a 90 degree ell downward and towards the middle id I want to do a center inlet IC , and if not , I will do a custom end tank I guess . If there is an OTS intercooler I can get I will do that .
Hopefully I can fit one in there , and the closest spot (crank pulley) there is only 5.5” of space
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So now that the engine is sitting in the car- not for good, but anyway I can finish the exhaust header, so I have three things left to do . Weld the head flange on without warping it , weld the turbo inlet flange, and finish the wastegate .
I took the strongback and drilled the proper holes in it so I can get bolts and fasten it down right before I do this welding , the flange is only barely tacked in right now .
The strongback is thicc as hell and milled perfectly flat , so I’m hoping if I bolt this down tight and don’t weld too much in any one area , let it cool, repeat , it should be ok.
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I then need to trim the collector and weld on the turbo inlet V-band , again , without warping it . Not my specialty ...

Then after than , I can get the WG feed pipe and flange on. I was planning on using 1.5” sch 10 for that and putting it at a slight angle.
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Re: The 90

PostPosted: Fri Aug 09, 2019 4:58 am
by DE80q
That should be strong enough to keep the head flange flat. The "T" structure will help with that a lot.

As for the V bands, a long time ago, I made up a buch of thick aluminum V band plugs for Tim. They were solid aluminum, and were used as back purge locations as well was heat sinks. From what he has told me, they worked very well to keep things flat while welding.

Re: The 90

PostPosted: Fri Aug 09, 2019 5:51 am
by Afterthought
Yeah I think last time I did this I welded it with it clamped to the turbo hot side ha. I should make some of those plugs though, on the lathe. be real nice to have a few.

The 90

PostPosted: Fri Aug 16, 2019 4:45 am
by Afterthought
I’ve not had a break from work yet but I received a few things I can try out .

Throttle body with flange , hopefully I can adapt the TPS to it ,
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The cast inlet piece from vibrant .
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Hopefully with those two parts I can decide whether the TB should go straight on the front or curve and then add the TB ... and this maybe will help decision on intercooler size /inlet location

The 90

PostPosted: Sun Aug 18, 2019 1:58 pm
by Afterthought
I asked a friend what intercooler is good for b3 and he recommended Treadstone vertical flow . So if I look at those there are two that right off the bat appear to be a decent fit for the space I have .
TRSTP (center outlet, passenger side inlet)
TRV25 . Side inlet/outlet

I think the center outlet would be preferable but a little tighter fit . It would be similar to what Jim has except not as cool because I couldn’t bend the runners right for my intake manifold, to make my inlet on the bottom like his
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I tried making a model of the TRV25 and I can see that I would have to remake the end tank as the outlet points directly at the headlight . So I could point it straight back and lower the intercooler possible
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if I was to do center Inlet I should be able to make this work . I may have to shorten the throttle body and shorten the elbow more.
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Re: The 90

PostPosted: Sun Aug 18, 2019 2:42 pm
by audifreakjim
I've been real happy with my treadstone vertical flow. From the pictures, it looks like using a silicone 45 to an outlet pointing strait up on the drivers side may be the best bet. I think it's going to be tight trying to get that in the middle unless you go with a shorter core. Or move the intercooler over towards the passenger side and make a custom cross member. That's what I did, I you look close, mine is not centered.

Re: The 90

PostPosted: Sun Aug 18, 2019 5:28 pm
by Afterthought
Yes , it looks quite like your setup and that’s why I was thinking I may be able to use that intercooler . No matter which route I go my intake will have more bends .
The more I work on it i realize how genius your Audi sport dual plenum Manifold is , having the TB directly on the front like that .
I was going to go for it but I couldn’t get the bend right on the runners . Image
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I did get an IE intake for revision 2 though, but I haven’t cut it up yet .

Re: The 90

PostPosted: Sun Aug 18, 2019 11:08 pm
by the german
I still vote buy a core and weld you own end tanks so it’s exactly what you want!

Re: The 90

PostPosted: Mon Aug 19, 2019 11:15 am
by Afterthought
I am going to have to order a radiator core too. No idea where to get that but I need to look at the sizing and see what I can get . The stock one ford at a tilt so I don’t think I will have to go too small

Damn this stuff is expensive

Re: The 90

PostPosted: Tue Aug 20, 2019 3:09 am
by Foscora
Amazing fab work!

Re: The 90

PostPosted: Tue Aug 20, 2019 11:57 am
by audifreakjim
I ordered mine from here, the core is very high quality http://www.theradiatorlady.com/

The 90

PostPosted: Fri Sep 06, 2019 8:57 pm
by Afterthought
Man I haven’t had any time to work on anything , but I set aside some time to install this used lift I got , so I could catch up on things that need to be done on the urq .
Now with that done I can dedicate this lift to the 07k project and hopefully keep moving along . I’m trying to mentally make a list of what needs to be done .

Aside from some straight sections of stainless , I have all of the parts I need to complete the intake and exhaust . I’m trying to source another 7163 to use with this set up so I can get the manifold flanged and in place , but before all that I’m thinking I will pull the engine back out , and revisit the clutch , flywheel, and starter. Once I make sure all that is good I can install the linkage and get the engine and trans set in place, figure out axle , do the intake and exhaust
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I don’t plan on doing anything with the engine just yet . I have a few of these engines in varying conditions and would like to see if I can get the car running and how my oil pressure and everything else looks before I build and put in the forged crank engine - hopefully that will work .

Re: The 90

PostPosted: Fri Sep 13, 2019 6:30 pm
by Afterthought
Damn this stuff takes a long time . I’m still battling with the header .
I have everything done but the wastegate take off now .
v-band flange is on and head flange is on and the great news is they are not warped which is a win for me .
I kept is as compact as possible but next time id do the wastegate take off before finishing the collector and for sure I’d leave more room for the bolts .
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This is the proposed wastegate location . Cut this 15 Deg bend in half , make it nice and short pipe and I’ll have to figure out how to drill a 1.5” hole in Sch. 10 321 stainless . Great
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Re: The 90

PostPosted: Fri Sep 13, 2019 10:53 pm
by alxdgr8
Carbide tipped hole saw?

Re: The 90

PostPosted: Sat Sep 14, 2019 8:56 am
by PRY4SNO
Plasma torch if you're fancy.

Re: The 90

PostPosted: Sun Sep 15, 2019 7:22 pm
by Afterthought
I’m afraid to take the plasma cutter to it but i guess maybe I could , then clean up with a dremel.

I might try the hole saw first

I happened to be out at my shop for a bit so I pulled the engine and trans today so I can revisit and finish a few things .
I need to finish the flywheel /clutch / starter stuff and get that solidified so I can move forward. At this point I can work on the linkage too , figure out how to attach the little cross bar on there .
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Re: The 90

PostPosted: Wed Sep 18, 2019 8:05 pm
by Afterthought
I will be working on getting some of the oil stuff laid out .
First I mocked up the IAbed mount .
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I was planning to run this piece but I overlooked that the mount doesn’t have a supply and return for the oil cooler .
So If I want to feed the oil cooler I need a sandwich plate .
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This is how it will all go together I think . This is the only filter I have but I will try and find a smaller one .
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The only thing I don’t like about this is it sticks a little into the space where my radiator would be . But I can go down from stock size on that or consider other mounting locations .

The 90

PostPosted: Wed Sep 18, 2019 9:16 pm
by Afterthought
The other thing I was looking at is the oil pump, The 07k has a variable oil pump and I can see there are about 3 different versions. All my engine block are “early” , 06 or 07.
It can’t really find any diagrams on it but it looks like the pump had a high and low pressure mode and I cannot tell how it switches between modes , or what reference pressure it uses .
It appears to be a 100% mechanical operation on this pump , The oil pump has a small shuttle valve inside that sees a reference pressure which I think is filtered oil. There is no solenoid .
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Anyway , I wanted to figure out exactly how the pump works , and if there is a way to disable this feature and have high pressure all the time not low/high . The pumps don’t appear to be interchangeable so it looks like I’m stuck with the old version either way
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