Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Good deal

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

I may be completlly screwed up but... how do you think that pump works? That is a diaphram pump correct? The pushrod pushes the lever which pushes the diaphram in, the internal spring returns it. If you apply boost pressure to the weep hole of the pump you will just increase the resistance on the diaphram and probably decrease the volume of the chamber and then the GPM. How will that increase pressure?

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

OK First off, I did not invent this wheel and I have the same problem imagining how it works. It does work, the only question is how much power it will support.

Here is how I see the pump working without boost reference:
1. The cam lobe extends the fuel pump pushrod causing the fuel pump lever to pull the diaphram upward compressing the spring (and also the air above the diaphram if it were not vented to the atmosphere) creating a low pressure area under the diaphram causing fuel to enter the pressure chamber. Important note: the diaphram spring does not appear to keep the fuel pump pushrod from floating, there is a second spring which serves this purpose.
2. The cam lobe receeds and allows the fuel pump pushrod to retract, releasing the diaphram (now under spring and atmospheric pressure) to pressurize the fuel under the diaphram.
3. Fuel enters the compression chamber through a one way flapper valve (may be two on the inlet side, but I could only get one to open)which opens due to the lower pressure caused by the raising of the diaphram and in turn closes to fuel supply as spring pressure is released downward.
4. Fuel exits through a single flapper valve which is open only when the fuel pressure pressure inside the pump exceeeds the line pressure to the carb.

So, by providing boost pressure to the atmospheric vent, fuel pressure rises directly with the boost as needed. I may be missing something, but this is very close. I hope I have provided a reasonable explanation.

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Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

I here you and that is the way had imagined it working. I still don't savvy it but... you try it and let me know what you find out.

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

i dont mean to be a dink but jic and AN are both 37* im pretty sure

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

I stand corrected, the seat angle is the same between jic and -xx AN and here are a couple of links to tutorials on the same. An abbreviated version is the main difference between the 2 standards are tolerances and fatigue life (-XX AN is approved for aircraft, aerospace and military applications.) Functionally interchangable but not the same specification.

http://www.aeromotiveinc.com/products/content_p.phtml?pk=68

http://www.parker.com/tfd/fittingsolutions/ANFITTINGS.pdf

Sweet, less work

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Eliminated the excessive amount couplings from the turbo drain flanges tonight and welded on the steel #10 bungs - now they clear the inner fenders. Removed the headers and finish welded the waste gate flanges and smoothed out most areas. Tossed the headers on the scale to see what each weighed and they came in a 19.0lbs each. Probably not much heavier than tube type headers due to the fact I have only one tube running to the turbo rather than 4. I am mulling over the idea of laying a bead of weld around the ports of the headers for sealing purposes or taking them to a machine shop and having them surfaced on a large belt sander.

Looks like I only must remove the A/C portion of the power steering pump to clear the down pipe.

As I am looking to relocate the fuel filter, the area directly in front of the alternator looks appealing...other than the fact the electric fan will be pulling hot air over it. I wonder if a small deflector would be enough to keep the fuel cool?

Also, need to find a good spot for the coil...seems like older engine used to mount them directly behind the carburetor - but I think that was on smaller diameter distributors, not HEI's.

I will probably order some 3 psi springs for the waste gates so I can at least run this thing before having to pull the engine to rebuild and lower the CR.

I picked up a 650DP off of EBay. At this point, I can't install the EV carb bonnet because I don't have a carb with the choke tower milled off - should arrive early next week if everything goes OK. I think I will go with an undermounted intercooler after seeing malihoochie's intercooler

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Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

real quick question, do you think one of those carb hats would fit under a stock hood? I havn't checked on my car yet as the motor is apart, I hope it will but i don't think it's going to

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Ordered the cold piping from racepartsolutions on Saturday. Used E-Bay carb arrived today and the parts for the carb arrived yesterday. Looks like I may be busy this weekend

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Very informative post. This is paralleling my turbo buildup...but seems this one is moving at a much faster pace. Weld ell headers are the only way to go...at least for budget builds.

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

I can't tell you if it will fit under a stock hood. Depends on what intake, spacer etc. you have. The height appears to be about 4" without the 1" spacer. The spacer may be required depending on the direction you would like bonnet to enter.

I've tried. I'm trying to give back in a similar fashion as others on this board. If others were tight lipped about how etc, etc, etc worked, I would never have started this project. My goal (aside from building my own turbocharged creation) was to clear up any loose ends keeping someone from making an attempt blow through turbocharging. I have learned (read f'ed up) along the way, but I post the information so the next person does not fall into the same predicament.

I seem to be slowing down a lot. Starting back to class is a big influence but also the planning is more involved for the cold side, intercooler and carb because many of the parts cannot be picked up locally. The headers were mentally easier if for no other reason any problem could be welded.

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Well, here is the intercooler I bought. I am going to bottom mount similar to Malihoochies. Hopefully it can handle what twins will pump out. Any comments?

Mount...................................Top Mount
Length (Core)........................20"
Height..................................11.5"
Height (Core).........................8"
Thickness..............................4.5"
Inlet.....................................1.25" x 3.38"
Outlet...................................3"
Compress Air Flow Rate...........<600Cubic Feet/Min, Rated up to 600 Max HP
Working Pressure:..................35~40PSI
Pressure Drop........................2~5psi@35psi; 0.2~0.5psi@15psi
Hot Air Temperature..............32°F~302°F (0°C~150°C)
Material................................100% Aluminum
Design..................................Bar and Plate
Construction..........................Machine Cut and Stamped, Hand Welded
Finish....................................Polished
Net Weight...........................24 lbs
Fits.......................................02-05 WRX STI

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Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Starting to work on the carb. Running into a few snags/questions. The 1" carb spacer from Superior Airflow has somewhat small holes for the fuel bowl vent tubes to protrude through.

My question is how much (if any) do these tubes need to stick up beyond the spacer? I think as long as they are not plugged, it should be no problem. But then I start thinking, if Holley did not think the fuel vent tubes should extend beyond the choke tower and base of the main body, why do they press in those steel extension tubes? Edit: To keep fuel from sloshing out of the fuel bowls under hard cornering and braking.

As I was trial fitting the spacer, it was apparent the easiest/quickest method to clearance was cutting down the primary bowl vent to match the secondary vent's height. I did not realize is how much shorter the pressed in steel tube on the primary side is compared to the secondary as it was aided by the height of the choke tower.

After I milled it down, I was able to drill out the main body and press the tube back into the hole but now the height is much lower. I would feel safer if there were no steel tubes at all. I mean, when I pressed it back in, I applied no loctite of any type and it seems this could be a potential engine damaging piece if it ever came loose. After some research, I've found a picture of a CSU carb which does not have these steel tubes. But, does this mean they can be removed without condsideration or has CSU given special consideration to removing these? They only equalize pressure in the float bowl to that of the intake air, right?Edit: I am going to remove both pressed in tubes for piece of mind.


Found another killer sight for information on Holley carburetors!!! http://www.tocmp.com/manuals/Carbs/Holley/H4V-4150-60-80/index.html

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Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

The intercooler and some of the cold piping parts arrived today.

Intercooler was from ebay - reddogmotorsports and cost $174.95 + 42.00 shipping and handling. Intercooler came well packaged and is surprisingly heavy. Took 5 business days to ship.

Each day I get a little closer. Looks like I'll have to get busy drawing/making up the flanges for the inlet of the intercooler as well as some kind of mounting bracket.

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

draggin in the vent tubes what i do is go down to the hardware store and get a 12 in peace od stainless tubing the same od of the oem tube and make my own longer one debut it the angle is 45 deg then i use the red locktite and press it in slow , so not to tweek it and make the hole egg shaped been doing this for years to modifiy gas carb to alky works good ...

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Draggin,

Hello - my first post here. Congrats on the turbo conversion - I also have a 406 mailbu wagon you have given me hope that a turbo conversion is possible. A couple of questions and observations as I read your posts ( thanks for lots of pix!).

- Curious where you have relocated the battery to?
- Have you considered a heat sheild for:
the master clyinder resovoir
upper control arm bushings
and inner fenders.....

Hate to see all this work get too hot......


efi-diy

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Batteries are in the spare tire well for traction as well as a remote solenoid. I got tired of the Autozone starter not turning it over when hot. I had seriously considered running 24V to the main winding of the starter if need be but the additional current was enough Notice the fuses near the battery, these are very important if there was ever a short between the battery and the fuse panel. I threw in a simplified remote solenoid wiring diagram for clairity.

I plan on wrapping all exhaust pipes under the hood.

If I could start over...way over, I would have bought the 2.5" Torque Tech exhaust rather than the 3" but who would have known I was going to try a twin turbo setup. 2.5" down pipe would clear a little better. But I'm not complaining, I will still have power steering.

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Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Looking good on the turbo build, Might need to put in a support bracket for your turbos to prevent cracking in your manifolds or eventual damage to your manifold mounting studs / bolts. (Thats alot of load hanging a pretty good distance away once you start hitting bumps). Also, I am not sure your battery disconnect will kill your car when you turn it off.
John

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

This is true. Luckily, the local tracks (IHRA and NHRA) are not very strict about this feature

I don't think the near 1/8" wall tubing will crack although, pulling the threads out of the heads is always a possibility. I will look into a support for the turbos which is based from the engine block instead of the heads.

 

Re: Budjet/DIY Twin Turbo 406 Malibu Wagon

Just thought i'd say your buildup is looking good man! I have been working on mine and now have a taurus fan that blows like mad and i got the NOS installed too! I used the new MSD digital window switch and mounted all my electronics on the dash for a real KNIGHT RIDER look. New posi, axles, big bearing housing ends and a catalytic converter. SAY WHAT? Yes a cat converter. I am going to try and pass emissions! Im going to go back to 1.5 rockers and put about .020 lash on it to kill the duration and let it clatter it's brains out for a day. Hope it works since if i got pulled over, it has 65 impala convertible plates on it! Heh heh. SHHHHHHH. Dont tell.