Build AUS BJ73 + turbo + arduino

[350HJ75]

today i clocked the turbo.

After being split with plenty of penetrating fluid still evident.

marked a new location for the locating pin on the exhaust housing, you can the original hole there.

and final position on the car.

 

[350HJ75]

also went to a local hose joint and got the oil feed line and oil drain line sorted

T piece in the block with oil feed going up and oil pressure sensor facing down

overview of feed line to turbo, they welded a dash 4 fitting onto the original Subaru banjo hard line.

so the oil feed line is

subaru banjo > dash 4 fitting > teflon/stainless line > dash 4 fitting > 1/8 bspt

the drain line is also made from the same teflon/stainless braid line and has an earls hose clamp / braid cover end on it. i have another for the sump end but i am waiting for a fitting to arrive in the mail before i tackle the other end of the line yet.

btw these teflon/stainless lines are $$$$! lets just say the two lines i has made today were more cost than the turbo itself. But i like the idea of nothing melting or catching fire...

I also ordered all the parts required to plumb up turbo to the air filter and the intake manifold so just waiting on parts mainly now

I am stoked with the amount of progress i have been able to make however.

 

[350HJ75]

minor update but whilst i am waiting for parts i installed the final arduino sensors

Installed RTD thermocouple behind the grille for ambient temp

boost pressure sensor and IAT RTD also wired in ready for the inlet pipe

and added the two more MAX 31865 chips for the new temp sensors inside the box (two purple ones)

now the arduino is totally complete, the only thing i need to do is run some tests on the boost pressure sensor to make sure it is reading correctly.

 

[HomerOz]

G'Day Fella's,

Most impressive.
You have been busy 350HJ75, and you are a very handy Bugger as well.

Best Wishes to all for 2018!
Homer

 

[350HJ75]

got another day down on the cruiser since parts have arrived.

EGT bung welded into manifold

and die ground out the inlets from the head just to smooth things out a bit

 

[350HJ75]

had some pipe adapters bent up at a local exhaust shop and beads welded on to help hold the silicon joiner

air filter to turbo inlet pipe

crossover pipe from turbo outlet to manifold inlet with temp sensor and boost sensor bungs welded in.

 

[350HJ75]

sump removed and an oil return welded in using an old hydraulic fitting elbow with a bung and fitting on the end.

you can see the yellow line is the max oil level based on the dip stick - about 50mm below the flange if anyone needs it for future reference.

welded on the inside also.

cleaned up the bottom of the block of the old cork gasket (fun job upside down with oil dripping on you) ready for the sump to be put back on with ultra grey rather than getting a new gasket.

 

[PATHnz]

Presumably you had to modify the brackets and hoses for the power steering reservoir relocation? I guess you have an inline pump since there's no fuel filter next to the brake booster. Had a look at mine today, one power steering line needs shortening and the other needs lengthened.

Any plans for the accelerator cable? Will it be near the turbo or will you re-route it from stock?

 

[350HJ75]

Presumably you had to modify the brackets and hoses for the power steering reservoir relocation? I guess you have an inline pump since there's no fuel filter next to the brake booster. Had a look at mine today, one power steering line needs shortening and the other needs lengthened.

Any plans for the accelerator cable? Will it be near the turbo or will you re-route it from stock?

yes power steering reservoir has totally custom brackets, was a bit of mucking around the keep it level and above the power steering pump. there was an aftermarket filter/water seperator in that location but i removed it since it was leaking.. the factory filter is still in place above the inline pump.

hoses i think i had to lengthen both, i purchased some fuel hose and used that.

my current plan for acc cable is to use the stock cable and run it over the compressor housing but in front to get it away from heat as much as possible, i think i will need to heat sleeve it anyway and get some brackets to hold it in place.

 

[350HJ75]

finished off putting the sump back in today

used ultra black gasket maker

and turbo drain hose in final position (pictured from underneath)

 

[350HJ75]

final position of EGT probe, i think i mucked up a bit here as i cannot removed the probe with removing the manifold which might come and bite me later but we shall see.

also welded some nuts onto the turbo flange to make installation and removal easier

and re-created the mount to connect the power steering pump support.

this completes all the work on the manifold so it is off to have the flange machined this week then it will be ready.

 

[350HJ75]

put hose clamps on the injector pump vacuum lines. thanks MUD forums for the tip! happy to avoid a runaway diesel situation

 

[350HJ75]

I mocked up the whole setup to have a look at the accelerator cable routing, i am very happy with how simple looking it has turned out.

and this is my most likely path for the acc cable, need to make a few supports for the cable to keep it in place.

 

[350HJ75]

Since rotating the compressor housing, the bolts for the waste gate actuator no longer line up, so i measured that i had rotated the housing by 37 degrees and drew up the below bracket in CAD. You can see that it simply rotates holes A and B 37 degrees to position A' and B' on the same diameter to put the waste gate back to its original position. This has been sent off to the laser cutters to be cut out of 3mm stainless plate.

Once this bracket is on with the wastegate actuator and the manifold is back from being machined i will be ready for first startup! getting close now.

 

[HomerOz]

G'Day Fella's,

Looking good 350HZ75 and thanks for sharing.

D'oh!
Homer

 

[350HJ75]

G'Day Fella's,

Looking good 350HZ75 and thanks for sharing.

D'oh!
Homer

Thanks mate, appreciate the positive feedback

 

[350HJ75]

Today the waste gate actuator bracket arrived.

positioned on the compressor housing.

and the mamba adjustable waste gate actuator bolted on, line up perfectly! i need to trim back the female threaded section on the connector to the waste gate flap as you can see i have it fully threaded on and lost any adjustability.

 

[350HJ75]

flanges came back from being run on a belt sander

so tonight i was able to do the final assembly and this is the result!

I primed the turbo with some oil from a syringe down the inlet hole and after about half an hour it started dripping from the drain pipe, as you can see i have put a container here for now so when i start it up i can check for oil flow before connecting the drain hose to the sump.

I was tempted to start it tonight but i will sleep on it and do it tomorrow after work, give me a day to think of anything i might have forgot

 

[HomerOz]

Lookin good 350HJ75!
Also looking forward to the post start up run report.

D'oh!
Homer

 

[350HJ75]

And we have boost!

started it up and waited for oil coming from the turbo drain, came through ok so I hooked up the drain and went for a spin.

I had the 5psi WGA spring in at first but was only getting 1-2 psi max with 3mm preload on the actuator arm, car felt like it had a bit more power but nothing to write home about.

So as a test i changed to the 12psi spring and kept the same 3mm preload on the actuator arm. Now we were cooking ! as the car was making some noticeable power! boost was reading about 7-8 psi with a peak of 10 so i think maybe some more pretension on the WGA might get me to 12?

Anyway so far i am very happy with how it is driving but tomorrow morning it is booked in for a full exhaust, so will get that done and then start doing more adjustments and more driving!

the only issue i have had so far is that the seal from the turbo oil drain is leaking at the flange so i need to get another gasket or just use some permatex ultra black on it.

below is a quick video of the test drive around the suburbs with the 12 psi spring