So a little Friday night update for anyone coming in from the pub!
I took the turbo's to the machine shop today to get the housings done. I use a small machine shop in Woking that I've used in the past for head skimming. Couple of old boys with what looks like a workshop from the bowels of the Titanic but they are very good. I had already got a quote from another shop and they wanted £120 a turbo for the work as they said it would be tricky! Needless to say the shop I went today are going to charge £20 a housing or £40 a turbo! I think this is a really good result as it means the price is being kept well within check.
As with all turbo's there is a required clearance between the housing and blades. This has to allow for heat expansion and centrifugal forces that might cause the blades to touch the housing. Also the clearance has to be tight enough to maximise the airflow and enough to minimise the contact possibility.
Having read Bills post he kindly put up on page 1 from seatcupra.net and measuring the original turbo I had (0.48mm) the clearance of 0.50mm has been decided on and the housing are going to be machined to this.
I hope Bill doesn't mind me quoting him but this is a bit he wrote on the other forum.
I make a call to CR to confirm whats deemed the correct/acceptable clearance.. 0.020", give or take 0.05" - which is 0.508mm clearance, plus or minus 0.127mm (min 0.381mm max 0.635mm) These are Barn Door Tolerances... and exceeded anyhow.
Now the thing to bear in mind this clearance factor doesn't allow for the surge proctection afforded by some hybrid makers, and as I'm not using a cutback blade I have decided to take another approach. This is going to be a little bit of a trial but as this turbo is a project believe it's a good place to try this, who knows it may be good option. I have borrowed a design used in jet engines which smoothes air flow through a jet engine in order to prevent surge. The only thing I can't do is use Vanes and stators, which smooth the air flow making it more efficient but I can use a design which will allow increase airflow around the turbine blades at high pressure but wont reduce the clearance around the housing and turbine blades.
It will be easier to show the finished item than try to describe it so as soon as it's done I will post but it's a very simple modification.
In my quest to build this turbo I have come up with a few questions based on other hybrid builders specifications.
1st. It seems that most builders, in their specs, use a 360degree thrust bearing. This is sold in some cases as an upgrade. I don't really understand this as all BW K03/K04 turbos use a 360 thrust bearing as stock. Seems a little odd. Are there different types of 360degree thrust bearings?
2nd a lot is made of lightened shaft wheels, which are sold as a faster spooling turbo. My only problem with this is that while it may spool quicker it also spools down quicker and also doesn't have as much potential energy stored, which in my mind can only increase the likely hood of surge due having less energy to fight the compressor stall. It's much the same as having a lightened flywheel in your car, it's great for 0-60 but rubbish when you need that stored energy when you go up hills etc and preventing stalling.
As you can see from the photo below there is a good chuck of metal removed from the end of the turbine shaft compared with the RS6 shaft I posted on the 1st page.
I hoping maybe someone can answer the questions above or at least offer some explanation to them, I am not critising any one elses design just curious. Appreciate the chances of getting answers is pretty small as it's all closely guarded!
As I'm making 2 turbo's up I have also been speaking to andyc-s3 with regards to him possibly using one of them in his car as another test bed, this will all depend on whether we can sort something out, but as I am still on the look out for a project car myself it may be a possibility
So how much has it cost me so far?
Well.. If we exclude the donor K04 as this can be one you already have or buy
RS6 turbine wheel, 2283 S3 compressor wheel, Full balance and full rebuild kit £270 delivered
Machining of both housings £40
Total so far £310
Obviously this is just the parts and doesn't include rebuild costs, but it's not bad considering you can spend more on low milage 2nd K04's!