76er Swallowtail K-Jet turbo build

[Oneofthegreats]

Over the last few month's I've been increasingly getting bored & needed something to do, other than help my friend's with there project's.

Which has led me to get motivated to continue carry on with phase #2 on the 76er, my daily since building it in May 08.



I've been gathering part's for the build over the last few month's for the turbo build up.

I thought I'd have a go at doing it "ol skool" style being a K-Jet turbo.

The spec is very basic & very, very mild. (only running 10psi, but maybe more if I can get the fueling right!) Nothing outrageous - Power expectation is unknown at this point. But hopefully it should be fun for awhile once sorted out.

Bone stock low compression "GX" "SLUG"
Autotech 270 Cam & Valve springs
Modified G60 intake
Ol Skool "BIG" Weber/Redline Throttle body I found. (This was a common mod to replace the stock twin throttle body in the 80's & can be a pain in the arse to find one)
Same stock Volvo K-Jet I've already fitted, except deleted Aux. air valve & Cold start valve
Audi 5000T boost referenced Warm up Regulator
Stock modified Distributor
ATP Cast 8V exhaust manifold
Saab T3 oil/watercooled turbo. V-Band 3" wastegate/dump pipe
Mitsubishi Galant VR4 Intercooler
Custom 2.5" exhaust & 2" intercooler piping
Tial 50mm BOV. (I'll be using this for my next project in the future.)

I'll also be fitting a Innovate Motorsport's wideband Air/Fuel meter/data logger to help me with the tuning side of thing's along with a modified Autometer fuel pressure gauge setup & also my favorite part. A genuine Callaway boost gauge, as fitted as part there Mk1 turbo kit's in the 80's!
I'll be tuning this myself, as there isn't a hell of alot of people out there who can successfully tune this sort of injection system, especially turbocharged too!
Once I'm happy with the tune, I'll put it on a dyno to get a idea of the power output.

I'm still waiting on some part's to arrive soon, but I'll post up what I've got & work done so far.

Saab Turbo & boost regulator (Just have to remove a broken bolt from the exhaust housing! DOH!) It's not a big turbo by all mean's (it's tiny to the other one I have here!), but it should be enough for now, until I get really power hungry. Only a matter of time! haha



New Engine Breather/catch can setup. I know. No more Powerade bottle! haha



Audi 5000T boost referenced Warm Up Regulator fitted



Autometer Fuel pressure tester I modified for testing purposes of the K-Jet, as this is how you basically tune a K-Jet system Note: the fuel tap to switch between "System" pressure & "Control" pressure



Weber "BIG" Throttle body





Test mounted up the intercooler to work out the bracket's & mounting after it was pressure tested. All good.



I placed it so it has full frontage coverage of the intercooler core & still has room to have the piping fitted. Once painted black, you won't even know it's there!



Had to relocate the Radiator back 1" & across to the driver's side 2" & then bend up a cover plate for the radiator core. Note: Underneath is is lined with some stick on foam to protect the rad. fins & keep it from moving.

[Oneofthegreats]

Intercooler with the mounting bracket's welded on



It's not a very big intercooler, but it will do the job easy as. A friend fitted one of these to to his TRX CA18T & on 20psi it made 199rwkw's & didn't have any trouble keeping the intake charge cool as!



Assorted boost piping & oil supply & return braided hoses & fitting's.



Volvo "Cobra head" K-Jet airflap intake boot



Innovate Motorsport's wideband A/F meter & data logger equipment





Callway Boost Gauge. (I've had this for year's waiting for the perfect project!)



Another Project that has been waiting in the wind's for a few years now. One day!




Stay tuned for more. Just waiting on part's now!

[Oneofthegreats]

Alittle bit has been happening in the way of Preeny helping me out with a custom adjustable one way valve for the warm up reg boost reference.













Now still waiting on part's to arrive.

[Oneofthegreats]

Well not much has been happening as of late due to other project's & job's to get done first. (see below),






Enough of that! Onto the intake.

I did get a chance to remove all the useless mounting boss' off the G60 intake I've got here & went & sandblasted it today at a friend's workshop. I also drilled & tapped one of the manifold fitting's with a plug, as I only need one port for the brake booster. It also came standard with a boost/vacuum fitting on the end, which will come in handy for the other component's


These intakes do look alot bigger, but these intakes aren't really suited to NA purposes. These are mainly for forced induction only, due to slow air speeds through the runner's on NA application's. You'd be better off with a properly match ported & bottom 1/2 half of the runner ported/blended.





Here you can clearly see how much larger the intake runners are compared to the standard 8V K-Jet intake of a GTI.
I'm also not running any cold start injector or a aux. bypass valve to simplify the setup & also less chances of boost leak's too!







Rest of the part's arrive next week, but I'll have to get these other job's done first.

[Oneofthegreats]

Another piece of the puzzle "finally" turned up this week too!

Weber Throttle body & Redline adapter!

Needs only alittle clean up. Very happy with it.

[Oneofthegreats]

Well I thought I'd match port the redline intake to the G60 intake as I've been motivated lately just to do anything around the house & in the shed, so I went shopping for some more porting burrs of different sizes & shape's, as I've already got a bluepoint die grinder & snap-on 8 carbide burr kit here.

But here's the problem. As much as I love going tool shopping, I bloody hate it, as I always come home with stuff I don't really need, or had future plan's on buying when the need arose.

All I wanted was some nut's & bolt's & a couple of porting burrs!

So here's what I ended up with -

8" Abbott Ashby bench grinder with a wire wheel attachment
M16 x 2.00 Tap
Various stainless nuts & bolt's for the project & shed supplies
Carbide burrs with short & long shank's of different shapes & sizes
Porting flapper wheels
WD40 gun & 4 litre container

Pic. time







Snap-on burr set & Bluepoint Die Grinder



Mounted up the bench grinder on an old truck drum stand I made ages ago



To match the other grinder/linisher & drill press on truck drum stand's. These are sturdy as all buggery & I got them for nothing as they were scrap. All it cost me was the metal to make up the rest of the stands

[Oneofthegreats]

On with the build

I dismantled the Throttle body for a clean up & inspection & removed one of the ugly brass fitting's it came with standard so I could plug it up.



Where the brass fitting used to be. You can see in a previous pic, a big tube style fitting hanging out of the side of it with a screw head on the end.



Get the Tap & cutting compound. This stuff is by far the best stuff I have ever used for cutting threads & even drilling!



Run the Tap down gently



New thread all cleaned up



Bung fitted & sealed with pipe sealant




Then onto match porting the redline adapter with the intake manifold gasket.

I didn't follow the line to the letter, as the material would have become very narrow even for the gasket, especially under boost pressure too, so I left some meat where it open's up the the bigger end!

You can see how much material had to be removed!

[Oneofthegreats]

Finished product. I finished it off with the flapper wheels. They work awesome at smooth everything out!

Redline adapter



Intake Manifold



I blended in the opening into the first port runner as smooth as I could. I'm not a pro at this. Just enjoy doing it! haha



With the adapter mounted up. I tried to make the transition as smooth as possible without sharp edges or turn's & blended it into the manifold.

Came up ok I reckon





With the throttle mounted up. I also tapped & inserted a bung into one of the fitting's I didn't need in the intake too. I only need one fitting for the brake booster.





Open wide!!!!!






I'm not too worried about port matching to head at the moment. If the engine blows a headgasket & I remove & dismantle the head, I'll do it then. But can't be stuff with the engine still in the car.

I'll also do the exhaust manifold too when it turn's up, but I'll only match it to the exhaust manifold gasket's.

Enjoy

[Oneofthegreats]

Well I've been flatout here lately, with car shows/event's & other general service stuff, but a big shipment has finally come in & everything has been going full steam ahead.

Heres the latest shipment of part's. Mainly the main part's I've been waiting on to get things going



I decided to get a Tial BOV with V-Band, as it matchs a Tial Wastegate I've got here for another engine build later on



Internal Wastegate assembly which transfers into a 3" V-Band







BIG difference to the standard Saab exhaust/wastegate assembly & the "whopping" great big 2" dump pipe! Very restrictive too!





The all important 8V cast exhaust manifold



Various gasket's, adapters & oil fittings



Some new brakes, as the old ones are, well old & warped!

ATE Power disc's front & rear. I got some 280mm for the big wheels & some standard 239mm Ive I ever decide to put smaller wheel's on to drag it

[Oneofthegreats]

So with nearly all the major parts in hand, it was time to get thing's moving along as fast as possible

Before Engine bay shots







Didn't take too long to strip it all down & start mocking everything up & then came across some trouble! All this kit is for a LHD car! DOH!

There will be a few mod's here & there to get everything to fit O.K.!

But after scrounging through some various nut's, bolt & studs & even having to make different bolt's with the help of Dom, I finally got there

Fitted up the ATP 3" wastegate V-Band adapter in the process

I painted all the cast exhaust manifold, turbo housing in VHT High temp Matt Black . Awesome stuff & the rest of the dump pipe will get the same treatment







It's a bloody tight fit! It's less than 5mm off resting on the steering shaft boot! Ah well. The old extractor's rested on it anyway!

[Oneofthegreats]

Assembly mocked up on the bench with a few more part's fitted











Mocking up a new Wastegate actuator.

I can see why company's such as Callaway etc all ran external WG. There is bugger all room down there for them. But I've come this far not to turn around, so I'll stick at it & make it work









Then the die grinder had to be broken out again due to clearance issues with the G60 intake!

This took quiet some time & alot of fitting & refitting to get it right

[Oneofthegreats]

With some of the stuff off getting finished welded & a few other part's I'm waiting on, I decided to tackle some other part's incl. modifying the dizzy.

Early "twin port" vac canister





Stock GTI vac advance canister



To enable more boost retard, I drilled out the vac pot stop





All mounted up after drilling some new mounting holes





I also fitted a set of MK4 GTI 20vt spark plugs too. This should finish off the ignition system with only a couple of minor timing adjustments during tuning

I also decided to have another play around with the Audi Warm Up reg after some long thinking sessions.

The more I played around with it, the more I learned about it & decided to apply the boost pressure to the other chamber of the warm up (not the barbed fitting side) & put it to the test. I wound down the compressore to 10psi & put it to the test. It worked spot on & I played around with different pressure setting's & compared them to some old porsche K-Jet turbo spec's & were right on the money.

I no longer need the one-way valve my friend made for me.



During my thinking stage, I also wanted to try & add more fuel enrichment for higher boost level's, but didn't want to go down the programmable extra injector(s), as this basically defeats the purpose of building a K-Jet turbo. If you've got one or two extra injectors that can be programmed the way you want to supply the fuel, you might as well go to a full standalone ECU like Microtech, Autronic etc.

So I've had a flat plat of alloy welded to the face of the intake plenum & have drilled & tapped holes for an extra 2 cold start valves run off a adjustable hobbs switch.
Because the G60 intake doesn't have a spot for it, I can put them where I want. The stock GTI spot isn't efficient enough to mix up the right mixture anyway, as you've got say 10psi blowing right as the face of the valve, which will just blow the fuel right up against the No1 plenum wall & force it all into cyl. 1.
So I've placed one of them between cyl 1 & 2, & the other between cyl 3 & 4. Hopefully this with mix it up nice & supply an even amount of fuel to all cyl's.

Even if this setup runs rich as buggery on boost. It's better than running lean! Running rich can also drown out the piston melting pinging! We'll see how it goes. If it does run on the rich side under boost, I'll screw some more boost into it & see what happens.
My friend is also good with setting up water/meth injection kits as well, so theres another option too.
I plan on starting off tuning on Wastegate spring pressure which is roughly 7psi & work my way up.

In the event of it melting a piston, I've got some 20vt spare piston's & rods, I'll throw in along with a G60 metal head gasket, which should be more than enough for the little 8v

I'll put up some pic's when I get the intake back.

[Oneofthegreats]

More pics

Various silicone hoses of different sizes & shapes. (What ever doesn't get used will get put away for the next turbo build) I't shard to judge what you might need when building these sort's of things without having most of the stuff already fitted.



Various mild steel mandrel's & piping.



A couple of my friend's came down & built the dump pipe while I was at work & also installed the oxy. sensor bung. They done an awesome job too smoothing off the welds & making it flow nice & smooth. They'll also be helping with the intercooler piping.

I'll drive it to my friend's exhaust place like this & he'll rig up the rest of the exhaust. It will just be a 2.5" with a resonator & turbo rear muffler. Don't want it too loud as I travel 200km a day in it. So no drone for me!
In case your all wondering, this is my everyday car & travel 700+km a week in it, not a weekend warrior.







Hobb's switch & Mk4 GTI 20vt (AGU engine code) spark plugs



A good friend of mine also gave me this.

A factory 1977 Mk1 GLS Radio.

[Oneofthegreats]

Well, I finally got my intake manifold & intercooler back!

These were the last piece's in the puzzle from stopping my progress.

Now on with some more work

My friends tackled the dump pipe, so it was my turn to do the rest of the pipe work. Good fun!

Intake with it's modded twin aux. injector (cold start valves) plate







Hopefully it should work ok. If not, the weber throttle body has another mounting for a 3rd cold start valve.





Intercooler with all it's mounting brackets on



Mounted up the intercooler & then installed the radiator to start mocking up all the piping



There is still alittle bit of room between the intercooler & radiator. They aren't hard up against each other.

I also mounted it using scrivet's (pop rivet nut's) Work awesome!

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Various silicone hose joiner slugs





Had to get the turbo intake pipe stretched to fit snugly in the volvo intake boot.



Turbo intake pipe all done & mocked up. I'll get some more pics of this when it's back out of the car along with all the pipes



Then started mocking up the intercooler to throttle body piping







Finished pipe





Then mocked up the Tial BOV mounting position & then the Hobb's switch as well