Tdic

[IceV_760]

Okay.. I get my project done week back.
Chinese IC, D24N/A intake manifold, then piping.
I cant say much about power, since there been raining snow now for few days,
it just spins throught 1, 2, 3, 4, and with gas you get it easily spin with 5th gear also. Sounds like Scania truck with 3" pipe.
Pictures later, and results.

[Jason]

Sweet, get us some pictures!

Jason

[IceV_760]

Tomorrow ill take pictures. I have some pressureleak there, tho,
but ill get it fixed.

77volvo245: i noticed you asking for pictures about fitting intercooler to d24
on turbobricks, i give you in MY mind better fitting than that horrible
looking self-made. I made it also with N/A intake, but it looks alot better.

[77volvo245]

That guy Matt (500dollar744ti) +T his D24 and I heard he hacked his car pretty good.

[IceV_760]

Hacked? What you mean?

[IceV_760]

Okay. Finally tooked my photos.
So i did it like this.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00398.jpg

First i unmounted frontbumber, and after that it looked like that.
Then i made rack to IC, and assembled IC there ( note i made it stronger later, rack i mean)

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00400.jpg

Then bumber back. I had to cut that extra plastic in back of spoiler,
where the three holes are. You know what i mean if you unmount it.
Well, after it, it looks nice.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC004012.jpg

I will make cover for that IC later, so rocks dont hit it straight.
Then was turn for piping. First, i changed intake manifold from TD one to N/A one. And tig-welded the hole on back of it.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00402.jpg

No rubber shit needed anymore. Then i turned cold side of turbo 180* degrees, so at the start points towards land. From there i get piping easily to IC by making 90* degree curve towards IC, and again on IC, 90* degree curve to connect it into it. Okay. Half of the job done.
If you want to make like me, you need to get rid of that visco,
otherwise it dont fit. So, 90* degree curve towards back of the car straight from IC with silicon curve. Then 90*degree curve again, and head of that pipe will come out in motor bay. Then little less than half meter straight pipe,
in angle of about 45* degrees. Then, connect big, aluminium/metal 90* degree piece to that pipe, and with silicon which grows from 2,5" to 3",
to IC. All that looks like this.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00405.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00408.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00407.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00404.jpg

Thats it. Grats, youve done your IC project. By the way, you need to cut piece of that sound-dumber cover under bonnet, at bonnet will close.
Ill have some pressure leakage somewhere near turbo at this moment,
and my dumb valve is broken. Some little more to do, but project is mostly done. Tooked about ~550$ from me, whole project, but by knowing what to buy, you will save 100$ from that amount. I suggest to do it that way, its
pretty easy and pretty cool looking. Feel free to ask if need to know something about assembly. Ill update when i get my pressure leak fixed and new/used dumbvalve assembled and buyed.

[Jason]

Looks nice! Get a pic of the car of the front so we can see what the intercooler ended up looking like from outside!

Where is your radiator fan?

Jason

[IceV_760]

No radiator fans assembled at this moment, i unmounted my 2 electric ones,
but havent bothered yet to re-assemble them since here is
now about 32*F, no heating problems at all.
Ill get pics tomorrow when i go to hall do my project further.

[IceV_760]

Yup.
Was spending nice hour on iced parkinglot.
That was unreal cool, i wonder why there isnt winter always, heh.

Back to thing. Tomorrow to garage.
Have pretty tight what-to-do list.

Fix my dump-valve (i found out its possible )

Put boost-gauge to work (will get done same time i fix dump-valve )

Add atleast one radiator fan (Temperature raised now when "drifting" on ice,
since bow was pointing somewhere else than moving direction,
and no driving breeze wasnt cooling radiator due to that)

Add oil separator ( I have one handmade, different system than Jason have,
one which wont blow them back to intake-side, it collects )

And pretty much in that order. 6 hours time. I hope to get all that done,
but possibly i dont get. After that list is done, if i havent forgoted anything,
then will follow tuning smoke-amount to optimal, and then to bench.

Sidenote: After driving, you could get freezing-injury in your hand,
so cold is the intake manifold, sad i dont have laser-heatmeter,
but when outside is 35*F, i can bet intake-manifolds temperature
is somewhere 45*F. Even whole motor glows heat.

[Jason]

Why are you wanting to run that dump valve? If your going to push more than stock boost its only going to need to be plugged anyway, why not just delete it all together?

Jason

[IceV_760]

Okay, electric fan assemble, done.
And i think dumvalve works.. I get same times than
before project, on 0-100km/h acceleration.
Just need to get that freaking boost valve to work,
so i can start bleed it.
I wasnt able to come up with the placing of oil separator yet.
Then i get bored and left after 5 hours.

Oh yea, pictures for you Jason.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00420-fake.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00421-fake.jpg

In my mind it looks pretty cool.

[77volvo245]

Looking good man. :)

[IceV_760]

Little update. Turbo broked. Not more about it.
That means, no benching for a while. Good reason to buy better
than that squishy to3 garret. Ill inform later at where i come on whats the next turbo.

[IceV_760]

Ladies and gentlemens.
I have bought "new" turbo..
Garret GT2556v VNT-turbo.
New technik, i think that will make temper of my car awesome.
Pics and alot reports incoming on december!

[jbg]

IceV_760,

Sorry to hear about your turbo breaking, but congratulations on the new one! Your workmanship is very nice, I'm always impressed by the work I see on this board. As usual, keep us updated on your progress. Us North Americans are always intrigued by what our European friends are working on.

[IceV_760]

Nice to hear someone read this, and likes.

http://www.youtube.com/watch?v=KgVrpiFfp8U&feature=related

Here is pretty clarifying video about how VNT works if someone didnt knew it.
It has alot pros versus ancient to3:s and other by-bass turbos.

With VNT you gain early wakening, mine should wake up somewhere about 2000rpm's. Compare that to to3, about 2500rpm's. It will roughly pull up to 5000rpm's. To3, power vanish somewhere about 4000rpm's. Thats 3000rpm's useful "drive-zone" compared to to3's ~1500 rpm's. And it will pull alot
more pressure than to3 can before pressure on exhaust side grows too high.
And you can tune alot more specifically at where turbo wakes up,
how much it will evolve boost etc.
Cons are at jig-wings can tangle, and you need to use
some more effort to control it.

Thats best you can ever hope to your d24, vnt just makes engine
alot more comfortable to drive.

Above text was collected from few sides ive read, and some about
what i know. Just trying to explain my VNT-choosing.

[jbg]

IceV_760,

How do you plan on controlling the vanes of the VNT? I've seen a few threads on some VW diesel forums, such as mechanical linkages off the throttle linkage at the injection pump. What are you thoughts for this?

"libbybapa" on the VW GTD forum put a GT2559v on his Mercedes 3 liter 5-cylinder, perhaps this could give you some ideas if you don't already have a plan in mind:

http://www.vwdiesel.net/forum/index.php?topic=10365.0

Keep us updated on your progress!

[IceV_760]

Finnish forums are full of different mechanics to mechanically control
VNT ^^

First i just use one pressurevalve, which i bleed, and add electronic solenoid
at i can drop pressure when driving on highway.

That will be stage 1 to get it back on road fast.
Then ill start to build longger visioned one which will
allow more specific control over VNT.

[volvo d6]

I like it:D

[Jason]

I'm quite interested to see how you controll it.... I have been toying with the idea of using a Holset HE351VE turbo off a 6.7 cummins. The exhaust side can be closed down quite small so even our small 2.4 will spool it, its got a 60mm compressor, and they are cheap around here!

Jason

[IceV_760]

New beast arrived.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00424.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00425.jpg

Little dark photos, but its a evidence its now here.
Its on really good condition. Feels like earlier christmas^^

[Slobodan]

That is a nice looking unit you've got there.
What are the specs on this unit?

[Jason]

That should be fun. I expect pictures, and video with sound!

Jason

[IceV_760]

Yea, it will be fun. I taked better pics now.

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00426.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00427.jpg

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00428.jpg

cold side was .54 a/r and hot side .64 a/r (if i remember correctly) , and 84mm trim. but its VNT which allows it to start spool early, and with those monster numbers compared to to3 it will spool alot higher and evolve more boost.

Just dwaring pictures from "flange" to get it ordered.

[IceV_760]

Little update.
I choosed not to make new exhaust manifold, i just make adapter between t3 and gt flange, which will also turn flange 90*deg. up, so oil-lines go correctly.

[Jason]

Why not just loosen up the housing and index it differently?

Jason

[IceV_760]

Atleast in this VNT you cant turn exhaust side housing.
That makes doing 90*deg. curve to only solution.
I ordered first flange today, they promised it be done atlast in friday.
Then i need one flange more.

[IceV_760]

Long time since writing last time there.
Atleast i got my time to start the project.
Unmounted old Garrett t0307, which suprisingly isnt broken, just installed
wrong ??? but well, i have new one and i will assemble it.
I need to do new oil-lines, new downpipe, and doing new exhaust pipe
with same effort, 3" of course. And adapter plate to fit
gt2556v to original exhaust manifold. Flanges should arrive this week,
atlast in friday. Ill take pics.
After all is assembled, harder part starts. Making that VNT work on that
stone-age diesel^^

[Jason]

Sounds cool keep us updated!

I'm especially interested in how you end up controlling the VNT.

Jason

[IceV_760]

Just heard flanges are on their way.
4 flanges and 2 copper seals costed total ~120$ in your money,
its cheap atleast here in finland.
At tuesday adapter plate should be done and turbo fitted,
then on thursday will make oil lines, and friday atleast downpipe,
so i get it to drive again (damn ive been missing driving with my volvo.. )
and i can use christmas vacation to build control system
to that VNT. Cheers.

[IceV_760]

Well, long story short, shit:

http://i576.photobucket.com/albums/ss203/IceV_760/DSC00458.jpg

happened to my Volvo...
It tooked enough hit from traffic sign, at its not worth to repair..
So, im changing next to automatic transmission+b230f.
No worries, ill keep watching this forum still, one of the best ones.
Cheers, and good late christmas and coming new year!

[Slobodan]

Oh come on man, don't give up. looks to me like you can do a little body work. Goto the junk yard find a passenger door. and do some rocker panel repair. I work a Volvo shop that fixes many wrecked Volvo's and we've fixed some that were just done, finished looking. but I was amazed when we were done. drove fine and look all right after wards.

[Jason]

Man, sorry to see that!

B230f??? You wont be happy after the torque and sound of a D24T.

What I think you mean is your going to find a nice gas volvo with a useless B230f and auto trans, and swap in your D24T!

If my volvo got smashed tomorrow I would just be on the hunt for another if I couldn't fix it. I would have a garage of spare parts off my current car and just get another going. Now that I finnaly got one, I enjoy it too much to just give up on it. Besides, I haven't reached its full potential yet!

Jason

[IceV_760]

Well slobodan,
it looks like bodyframe has changed angle when you look it
door opened. And floor under frontpassengers seat is raised.. :/
Yea, i know b230f is little squishy, but you can tune it aswell.
Have alot ideas already. Okay, actually right now,
going to look is it worth to buy. Cya later.

[volvo d6]

That 740 is ready for junkyard:) It is so many of these cars over here so he can easy get a new diesel volvo.

[IceV_760]

Well, volvo d6 is right.
I already have new one, and im loving how aw works with b230f.
Really nice car to drive. And that diesel.. selling it on parts.
End of story.