Dane's Hybrid Conversion Thread

[Dane]

Nice, this week is draggggggggggging!

 

[badger5]

not for me it is'nt

 

[Speedy Steve]

Manifold is looking good Bill dont forget mines next!

 

[badger5]

#1 & #4 runners attached..

 

[slappy_dunbar]

.. I have to say tho this mani is a proper PIA to make

Tell me about it. 18months in and I still don't have one which doesn't blow through its gaskets. The outlet to turbo MUST conform to OE dimension, or else the gaskets rupture. 43mm tops.

 

[badger5]

aye..

"lucky" mine is dimensioned from oe specs - hehe

its still a pia to make.. lol

 

[badger5]

pix of prototype k04 mani..
we will see how it fares..
not an ecconomic thing to make........ so dont expect many/any more......

enjoy.. (I know I have'nt)
tacked and test fitted in the bay.. This is V2 already..!

Collector

Respect to those peeps who make tubular exhaust mani's - they are a huge amount of time to do.
Yes this is a 1st off/probably one off, and the iterations to get pipes to clear the k04 turbo are a massive PIA... and time consumer.

anyhows.. Its bigger bore than OE, consistent bore through the runners, and a combination of 1.25" and 1.5" sch10 - 316L pipe fittings. Runners in 1.25" sch10, collector & joiner to #3 & #4cyl in 1.5" sch10.

Phew.. had enough of weldinh stuff for a while..
plenty of metal splinters embedded in my hands and fingers.. doh!

the plot thickens

 

[Dane]

Woop, cheers for the update Bill, might pop across this evening to have a nosey if thats ok. As said before I can't wait to see how it turns out!

 

[s3dave]

Is it up for auction.......

 

[Welly]

the plot thickens

As does the volume of metal in your bloodstream....

Looking good dude, very good in fact, hats off for the work gone into it.

 

[Speedy Steve]

Looks good Bill glad to see it loks easy enough to bolt onto the turbo unlike the xspower one

 

[Welly]

Looks good Bill glad to see it loks easy enough to bolt onto the turbo unlike the xspower one

Think that was one of the aims of the game in fairness, the XS one was a complete **** to fit.

 

[Westy]

the XS one was a complete **** to fit.

I think that's XS's motto isn't it!

 

[Speedy Steve]

Just a shame i dont know what to do about a manifold know

 

[badger5]

some comparisons:
K04 vs this prototype I've made

Some Design aspects I wanted to preserve, having seen and handled a "few" other manifolds.
1. It has to be bolt onto cyl head without use of "special" spanners. All fixings are easily reached with simple extension bar and socket.
2. The turbo bolts must be accessible.. from the top.. This will use M10 Cap screws not stock bolts.. Stock bolts will fit but their heads and associated sockets are too big.. and they round pretty easy.
3. Runners, need to be minimum port size and maintained throught their run to turbo
4. Standard size OE exhaust gasket is utilised, not anything too large where gaskets are unavailable.

 

[Westy]

sexy stuff!

 

[badger5]

Just a shame i dont know what to do about a manifold know

JBS one when its available

 

[Speedy Steve]

I think it will have to be Bill if your not going to make a V3

 

[badger5]

fitted with hybrid fitted (which needed to be clocked as it was'nt like std anyhow)
PipeWerx dp shown.
xs power one will need flange grinding (but dont they all!)

 

[Westy]

There's nothing quite like a good flange grinding

 

[badger5]

I think it will have to be Bill if your not going to make a V3

making another will be expensive - unless it can be copied in a low cost country the hours req'd to make this vs what people are prepared to pay...... is the question...

pay enough and another can be made -

 

[s3dave]

Is that Danes then bill? when you forget about the cursing and cut hands i would be more than interested....

 

[badger5]

Danes one yes.. Wellys oldun refurbished and made into v1.2 hybrid with its clipped turbine wheel.

 

[s3dave]

No i meant is that Danes manifold?

 

[Westy]

No i meant is that Danes manifold?

I knew what you meant Dave and I know what's going through your head

 

[badger5]

No i meant is that Danes manifold?

yes.

 

[s3dave]

I knew what you meant Dave and I know what's going through your head

lol it will be interesting to see his logs with that baby ....

 

[Lee172]

Looking good.. x 2 on the logs!

 

[badger5]

What are you expecting to see from logs. The reference is wellys results.

 

[s3dave]

The EGTS.....

 

[badger5]

Danes has egt so we will see that..
remembering remapped normal K04's already hit 920'c egt protection from their 250bhp levels

 

[Dane]

So update time,

The manifolds on and the turbos on! (not as straight forward as it sounds)

The milltek is in position, the injectors are in, the wiring has been repaired to the abs sensor, the n249 has been deleted and Bill is currently putting everything back together then it's mapping and water meth time!

 

[Dane]

Not a lot to take pictures of,

But this is the milltek, some pretty big tail pipes, bigger than I remember - pretty cool though

 

[cecilthesausage]

Lookin good Dane... Lookin good bet you can't wait can ya... Just like your first Christmas... Lol... Waiting for Bill to come down the chimney with his big sack lol...

 

[Sandip]

Looking well

Looks as though Pipewerx has changed their 3"downpipe slightly....

 

[Dane]

Haha! Safe to say I barely have any finger prints left from rubbing my hands together

 

[cecilthesausage]

We need to get S1LFH to organise a group buy on the mani..... Lol

 

[Dane]

I don't think there's anything Bill would rather do less at this point Lol

 

[cecilthesausage]

What another mani or do another GB with S1LFH or both lol

 

[<tuffty/>]

...The manifolds on and the turbos on! (not as straight forward as it sounds)...

Yep... it was not the most entertaining afternoon but I can now see how to get a K04 off with the head in place... I look like I have been self harming by the state of my forearms lol...

I don't think there's anything Bill would rather do less at this point Lol

Amen to that brother!!!

<tuffty/>