Builds 2F + (3F-E) = 2FETI Into My FJ40 (4 Viewers)

[matt.mcinnes]

To give a little more room around the engine for the intercooler I have electer to go with a remote oil filter drilling and tapping the original holes for the oil filter in the block and running hoses from them to the remote fillter, this will also allow us to fit an oil cooler inline too. the old mounting holes for the oil filter will be used to help mount the intercooler.

 

[Hulsty]

Drilled and tapped the M14x1.5 thread for the air temp sensor that will run to the Wolf V500.

The Wolf V500 also has the option for electronic boost control so you can map and control the way the turbo boosts up in conjunction with the throttle position by controlling the wastegate, also stops wastegate creep.

Hey mate just a quick question about your MAT sensor, that is on the outlet of the cooler right? Ideally the sensor should be place as close as possible to the inlet valves, IE in the end of the inlet runners to the head for the most accurate air temperatures. Just some food for thought

 

[matt.mcinnes]

Hey mate just a quick question about your MAT sensor, that is on the outlet of the cooler right? Ideally the sensor should be place as close as possible to the inlet valves, IE in the end of the inlet runners to the head for the most accurate air temperatures. Just some food for thought

If it's placed in the plenum it can be effected by heat rise from the engine, which intern effects hot starting, therefor the ideal spot is just prior to the butterfly on the throttle body. The original Air Temp sensor was part of the MAF sensor (not required we run a MAP sensor now). If you are running an intercooler it should be after the cooler and before the throttle body.

MAF sensor

 

[matt.mcinnes]

Pulled the Turbo apart today to alter the orientation of the exhaust and compressor housings.

Pretty simple just 6 bolts each side and retaining plates, once removed you just rotate the housings to suit your needs. Now the exhaust and compressor are opposite.

Compressor side 0.7

Exhaust side .063

 

[watrob]

Hi Matt,

What HP do you think this motor will put out when finished?

 

[matt.mcinnes]

Hmmmmm see sig line


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[agent orange]

Im speechless, this is so friggen cool.

Maybe some day ill borrow some of the less expensive parts of this build so my 62 can get out of its own way a little bit.

 

[matt.mcinnes]

Im speechless, this is so friggen cool.

Maybe some day ill borrow some of the less expensive parts of this build so my 62 can get out of its own way a little bit.

Tks glad your enjoying the ride, I was looking at the first post of this thread 1st Feb 07. Would be nice if it was all completed and tuned by 1st Feb 08.

I can't believe its almost year since I started this journey

 

[matt.mcinnes]

Well it's been a busy afternoon, picked up the intercooler water pump

Also picked up 2 x 65mm o/d aluminum round bar 100mm long, this will be machined into the converter from the Davies Craig pump to the 8 lines for the intercooler as well as a feed for the Turbo cooling. Just a ruff idea off what I have planned, this will be machined in 2 parts one to fit the hose tail water fitting seen in the photo and the other half to match the Davies Craig outlets. Once both halves are complete they will be welded together by Awill4x4 and then welded to the intercooler. this means the water lines to the cooler are kept to minimum. Rather than having 8 water lines running around the engine bay.


Then time for a chat with the engine builder about the cradle for the crank, hmmm it seems that we need to extend the sump around 20mm for clearance. Three options here, 1st we extend the sum 20mm overall losing ground clearance and possibly interfering with the front axle when articulating (have to check). 2nd we extend the oil pan 20mm overall and then take 20mm off the rear of the pan to bring the ground clearance back, possible front axle interference and less oil capacity. 3rd we do away with the oil pan, go to a dry sump and remote oil pump, no clearance issues, no oil starvation issues at any angle, no oil pressure/feed issues with the toyota oil pump. Only issue here cost

The good news is finally started work on the block, all 6 cylinders have now been re-bored and are awaiting honing.

 

[matt.mcinnes]

After reading and chatting with friends we have finally decided to go with this kind of TurboSmart BOV

Sleeper

 

[agent orange]

This is just some random bench racing, but i wonder if there is enough meat in the bores to cant the cylinders towards the thrust face so at tdc the piston is already exerting a force on the crank.

From what i understand at the higher power levels you can pick up a modestly significant amount of power. Food for thought since this is already the no holds barred ultimate 2fe build.

 

[matt.mcinnes]

This is just some random bench racing, but i wonder if there is enough meat in the bores to cant the cylinders towards the thrust face so at tdc the piston is already exerting a force on the crank.

From what i understand at the higher power levels you can pick up a modestly significant amount of power. Food for thought since this is already the no holds barred ultimate 2fe build.

Please explaine

 

[matt.mcinnes]

Turbo outlet temps

Spent the evening calculating Turbo outlet temps for the Garrett GT3082R @ 70F/21C ambient and from what I can work out at 9psi the outlet temp should be around 180F/82C at 15psi the outlet temp rises to 227F/108C.

Now if the intercooler is as good as I hope we should be looking at some good results.
If I have done my math right and built a intercooler that works.

Calcs using this.
Turbocharger Compressor Calculations

Also worked out a few more bits but it's 2:15am my head hurts so you can wait until tomorrow

 

[matt.mcinnes]

Bill to date This does not include the head work remember



This does not include the re bore and cam which is now on order.

Cam Spec's: Duration 220 @ 0.050" with 0.430" Lift, center Line is 112 Degrees Hope that makes sense.

 

[trekker]

omg! That is about $9,849 in USD!

Time heals all wounds. You'll forget about the cost soon unless you have a wife that constantly reminds you!

 

[matt.mcinnes]

omg! That is about $9,849 in USD!

Time heals all wounds. You'll forget about the cost soon unless you have a wife that constantly reminds you!

Just over $7000USD including the head for the engine build.

This does not included Turbo, ECU, Fuel System, Intercooler, Sundries the list is long and still growing

 

[tlc4x]

Huh? I thought you were in Oz. AU$4243 = US$3728. Still expensive but worth it if it makes you happy. Every time I read a new post here it makes me want to either do the 2FE or put the 3FE I have in my truck.

 

[matt.mcinnes]

Well after some long discusions with the Colin the engine builder over delays with the cradle and issues with now having to alter the sump to fit it in the idea has been canned

It looks like we are now going to replace and strengthen two of the 4 main bearing caps.

This to me is a big step backwards but Colin has are guaranteed, this will surfice, hmmmmm, and any failure due to it will be covered by him

I suppose like any great adventure it has its highs and lows, this been a real low.

 

[matt.mcinnes]

Huh? I thought you were in Oz. AU$4243 = US$3728. Still expensive but worth it if it makes you happy. Every time I read a new post here it makes me want to either do the 2FE or put the 3FE I have in my truck.

So far for the engine $8328AUS/$7399USD including head, but I am $2000 in credit at the moment but not for long

Also while typing the last post I have an email from Colin, he has elected to cradle the two new main bearing caps, tying them together as this can be done without altering the sump to much. The bearing caps at each end of the sump will remain the same, one of these the one at the rear already has 4 bolts which is good news.

Feeling a little more positive now.

 

[stereophile33]

This is just some random bench racing, but i wonder if there is enough meat in the bores to cant the cylinders towards the thrust face so at tdc the piston is already exerting a force on the crank.

From what i understand at the higher power levels you can pick up a modestly significant amount of power. Food for thought since this is already the no holds barred ultimate 2fe build.

offsetting the wrist pins on the major thrust side does the same thing.

agent orange is trying to bring up an oft debated engine geometry question. The 2F have such a long rod to stroke ratio that the piston dwell time and piston speed at top dead center and at PCP 13* aftd is extremely slow and thus prone to pinging on turbo motors.