[vtl]

Vband flange machining


A 100mmx56mmx30mm (Outside Dia,Inside Dia, length) 316 stainless hollow bar was ordered and machined according to the design.

The material machined quite nicely and there is now a nice tapered transition from the smaller diameter turbine housing to the diameter of the downpipe. Recently got a larger lathe which made this job fairly straightforward. The part turned out quite nice, a shame it'll be buried where it cant be seen!

[Socket]

Amazing work as always... everything you make is 100% quality !!!

[vtl]

Welded up the better vband flange to the downpipe


Shown here is the custom machined purge plug which ensures that the flange will not warp during welding. After welding the flange fits well to the downpipe and locates very nicely

The downpipe was built up to to the exhaust jig flush, but has shrunk slightly after all the welding. Fitment to the exhaust turned out quite good, well within tolerance

[vtl]

Welding the merge to the downpipe

This was a tricky part to weld as there is not much space for the tig torch to weld up the small gap. To make welding easier, i did not pre cut the hole inside, to prevent blowouts during welding.

This made the hole inside o the merge very slow to cut out, started off with a hole saw, then used the die grinder to shape it out. It was taking so long that the part was set up on the mill to cut some of the material out, and then the inside was finished and ported out with the die grinder

[Coupes33]

Excellent work Vince.

[vtl]

Finishing off the wastegate merge

The wastegate merge was finished out, the fitment of this pipe is critical as the downpipe is mated up to both the exhaust and wastegate. If the fitment is poor, then the parts may not actually bolt up at all, or excess stress is put onto the parts once they're bolted up.

Using the 3D printed tube method, a perfect fit was acheived, the part did have to be cut apart and retacked to acheive best fitment, and was a bit of a frustrating process, but got it in the end.

[vtl]

With the pipework done, the major parts of the project have been done and now onto the smaller items:

- O2 sensor bungs for downpipe
- 6an bung to be welded to water pipe for turbo feed
- turbo intake pipe
- finish off turbo outlet (done on vehicle to make sure the outlet lines perfectly up to intercooler)

Hoses (mostly AN lines)
- coolant feed line
- coolant return line
- oil feed line
- oil drain line (this may need to be fabricated out of hard pipe due to the tight bend required)

Finishing:
- Nickel plate engine bracket
- ceramic coat turbine housing
- ceramic coat manifold

[Socket]

Originally Posted by vtl

With the pipework done, the major parts of the project have been done and now onto the smaller items:

- O2 sensor bungs for downpipe
- 6an bung to be welded to water pipe for turbo feed
- turbo intake pipe
- finish off turbo outlet (done on vehicle to make sure the outlet lines perfectly up to intercooler)

Hoses (mostly AN lines)
- coolant feed line
- coolant return line
- oil feed line
- oil drain line (this may need to be fabricated out of hard pipe due to the tight bend required)

Finishing:
- Nickel plate engine bracket
- ceramic coat turbine housing
- ceramic coat manifold

Amazing attention to detail as always mate. The amount of work in preparing 3d models, jigs and level of problem solving is all the stuff that is unseen in a project like this. In the home straight mate.... kind of LOL

[Socket]

Originally Posted by Coupes33

Excellent work Vince.

Hes a legend isnt he

[jzx_andy]

Man, the attention to detail. Love it. Hopefully you will leave this one alone once it's bolted up and running Phil!

[Socket]

Car Audio Install - Continued

Started putting the final finishing touches to the audio system today, with the fabrication of the trim panels in the trunk.

This work takes a unique and creative mind, therefore is way out of my skill set

So Jay from Wick Wires and Coen from Fab Car Audio are lending a hand to do the design, fabrication and install (thanks fellas )

Today was simply roughing up the individual panels and test fitting everything.

Not much to look at for a full days work, but already an improvement on the loose wires and hardware

Will update with progress over the coming days

Pics 1 & 2 - Naked, wires, amps and whatnot, functional but not pretty
Pics 3,4 & 5 - Roughing in the trim panels to check fitment

[Socket]

making progress

[Socket]

Low Mount ST Continued
Been a while since the the last post. Work continues on the low mount with the ceramic coating of the manifold and turbo housing. Chose a chrome look over the traditional black for its superior heat management properties and because it looks nice as well
Vince installed them on the test motor, ready for the next stage of fabrication.
Big thumbs up Vince !!!!

[E93Seattle (Racerbruce)]

Originally Posted by Socket

making progress

it's quite faint, but i think socket's stereo can be heard in seattle!!!!

[Socket]

Originally Posted by E93Seattle (Racerbruce)

it's quite faint, but i think socket's stereo can be heard in seattle!!!!

Hahaha Hoping to get some more done on the trunk trim panels this week to finally finish the audio project

[Socket]

This weekend Vince and I nickle plated the custom engine mount using a pot, nickle solution and a camping stove. Who knew car modding skills included cooking

[Socket]

Been a while since I posted some pics. These from last weekend

[Torgus]

How do you like the car being that lowered?

I assume the kw v3 are somewhat similar to my Ohlins.

That is about an inch lower than how my Eibachs rode but when I switched to the Ohlins I raised it up an inch or inch and a half as I thought more suspension travel was a good idea.
Eibachs:



Have you ever hit the bumpstops? Do you have to set it 'hard' to avoid? Your build is awesome and I assume comfort is a big priority for you given all the work you have done with audio etc. Obviously weight is not a huge concern given all the dampening etc.


Have you ever considered the rear canards in CF that https://www.e90post.com/forums/member.php?u=137897 makes? here is a thread on them: https://www.e90post.com/forums/showt...1220561&page=2 I think they would look great on your car. This is not the most flattering picture of them but you get the idea:

[Socket]

Originally Posted by Torgus

How do you like the car being that lowered?

I assume the kw v3 are somewhat similar to my Ohlins.

That is about an inch lower than how my Eibachs rode but when I switched to the Ohlins I raised it up an inch or inch and a half as I thought more suspension travel was a good idea.

Have you ever hit the bumpstops? Do you have to set it 'hard' to avoid? Your build is awesome and I assume comfort is a big priority for you given all the work you have done with audio etc. Obviously weight is not a huge concern given all the dampening etc.

Have you ever considered the rear canards in CF that makes?

Hey mate, that looks great !!!

My car is a bit lower then I would like tb., I think the weight of all the sound deadening is making it sit lower then it otherwise would. But no issue with hitting bump stops or anything, just the odd scrape of the front lip on speed humps and steep driveways. All in all the KW3s are a pretty good kit. Not as nice as your Ohlins though

No have not really considered canards but now you mention it

[Socket]

work continues on the low mount. Unfortunately when Vince pulled the turbo off the car and opened it up, the turbine blades were damaged

Means we need a new super core

While we are waiting for it to arrive, vince is continuing the fabrication of the oil and water lines etc

[E93Seattle (Racerbruce)]

Originally Posted by Socket

work continues on the low mount. Unfortunately when Vince pulled the turbo off the car and opened it up, the turbine blades were damaged

Means we need a new super core

While we are waiting for it to arrive, vince is continuing the fabrication of the oil and water lines etc

oh no!
any thoughts as to what caused the turbo damage? was there any noticeable vibration or power deficit in its damaged condition?

[Socket]

Originally Posted by E93Seattle (Racerbruce)

oh no!
any thoughts as to what caused the turbo damage? was there any noticeable vibration or power deficit in its damaged condition?

no idea how it happened, might have been over spooling or something because I have been running with dodgy O2 sensors or some time. I didn't notice any loss in power or anything. Just N54 life