Posted: Fri Oct 06, 2006 10:43 pm Post subject: '72 bay with scooby turbo power
Well, here's the first few pics of my project. Thought I'd start by showing just what an arse-ache moving a heavy lump like this is when you've got no hoist or helpers at hand.
The motor has been sat in the load area of the bus while I've been getting the g/box, clutch, driveshafts etc in, and fabricating the engine support-cradle.
First I had to 'shuffle' it onto the ramps...
Then down the rediculous slide-type contraption (yeah, I laughed too) and onto a trolley which I hacked up to incorporate a small trolley jack for lifting the engine under the sump...
...which actually worked quite well
I then stripped everything off the top of the motor to make it as short as possible and fit under the back of the van without having to lift it too high. Plus the coolant manifold has to come off at some point anyway.
Next I jacked up the back of the van and slid the engine on the trolley underneath, and with a couple of tweaks on the trolley jack it lined up nicely.
There she sits, snug as a bug.
Thats where I am atm. I'll post some details on the support-cradle next time.
Joined: 27 Feb 2006 Posts: 878 Location: Tyne & Wear
Posted: Sat Oct 07, 2006 10:19 am Post subject:
Nice work m8... I used a very similar ramp trolly contraption myself when dropping the engine out the Covin
At the end of the day, it works and saves you having to wait weeks for someone to give you a hand
Look forwad to seeing more. _________________ DARREN
I LOVE RUST ME
Patent Pending "The Ultimate In Rust Remedy"
Posted: Sun Oct 08, 2006 7:35 pm Post subject: '72 bay with scooby turbo power
Today I made the mounting cradle for the motor using some 3mm thick steel plate for the end brackets, 40mm square section steel tube for the central bit, and 34mm round cds tubing, which slots inside the square section, therefore providing a bit more strength.
My motor came with the engine mounts hacked out (they had cut through the rubbers to remove the engine)
Now, Subaru charge £102-odd +vat EACH for these rubbers, and although I could have probably found cheaper second-hand ones, I wanted new rubber -trawled the net, ebay etc to no avail, but eventually came up with these...
which use an M16 bolt in either end, and come with (on mfrs website) all the technical specs about hardness, breaking & stress limits, etc. Loads to chose from, but this style is the toughest.
You just need to drill out one of the holes in the subaru engine mount-plate to accept the M16 thread and affix with an M16x20 bolt.
Incidentally, they make some in similar dimensions to the upper gearbox mounts, but in varying shore-hardnesses of rubber. I did have some from vw heritage, which were a different size to my originals ones and I ended up trashing the threads in them trying to screw in the bolts -also from heritage, and intended for the job! -Sorry VWH, You're spot-on otherwise. _________________ turbobay
Posted: Sun Oct 08, 2006 8:08 pm Post subject: '72 bay with scooby turbo power
... Next I drilled through the tubing to fit the engine-mount bolts, and mock it up on the motor (make sure the poles clear the cyl heads).
As you can see, the exhaust (and the stock turbo downpipe) won't clear it, but I'll be re-positioning the turbo anyway.
So, with the motor in-situ everything can be measured up,tacked together, holes drilled through the chassis and the end-plates.
Off again for final welding
...and a lick of paint. -Upside-down view, showing the slightly elongated mounting-holes (for easier fitting)
And finally bolted in for good...
Well, nearly... The chassis legs on the bay aren't too strong, and need some kind of spreader-plate putting on the outside to spread the load where the bolts go through, or weld a sleeve in through the chassis to stop it squashing when you tighten the nuts -but my angle-grinder died (thats the second one in six weeks!) -must invest in an air-grinder 2mo, so I had to stop there.
Anyway this is how it looks fitted -all strapped in nice and tight with all new rubber -ready to handle 280-odd brake (I hope! :smt112 )
It only LOOKS like it touches the sump btw, it clears by about 5mm.
'nother pic.
Summary: Measure, measure, mock-up, measure again. And again. And don't buy cheap tools -borrow expensive ones!
Hope that proves useful to anyone contemplating a scooby-bay install
Making a bracket to mount the turbo 2mo all being well. Bye! _________________ turbobay
Joined: 23 May 2006 Posts: 2527 Location: Mudway, Kent
Posted: Sun Oct 08, 2006 9:27 pm Post subject:
You've been busy
I made some 3mm plates to go on the outside of the chassis, make them long enough to cover the top and bottom of the rail. That'll make the whole lot stiffer.
I got ragged off cutting plate with a 1mm disk in the grinder (so did my neighbours). Pop along to B & Q and get an "Evolution Rage" circular saw blade IRO £25. These fit in a standard circular saw and cut 3mm plate easily. Wear long sleeves and goggles - the chips are red hot!
PS I haven't found air grinders much cop. Great for porting etc but cutting, nah! _________________ The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.
'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more
Bugger, missed out on "Live fast, die young"
Last edited by ElusiveStranger on Sun Oct 08, 2006 9:29 pm; edited 1 time in total
Posted: Sat Oct 28, 2006 7:20 pm Post subject: Eine kleine turbo
Ok, update time. Finally a few days off work
Took delivery of a few custom 2 1/2" exhaust parts from jetex t'other day, so have built the manifold/ turbo up-pipe, and brackets to mount the repositioned turbo
There's limited options as to where the unit can sit in a '72-on bay, because the rear crossmember and upper gearbox mounts (not forgetting the fuel tank) all are in the way. So repositioning the turbo is definitely an easier option than major body surgery.
Also to be considered is the heat produced by the turbo itself. In it's standard position the turbo is very close to no.3 cylinder on an impreza, and the heat in some extreme cases have caused problems with overheating. Always the cylinder nearest the turbo that goes first from what i've read and heard. So I've kept a good clearance.
There's heatshields, heat wrap etc to go in too, which all helps.
Another issue (of personal preference) is that fantastic lumpy burbly noise would be lost if the manifold lengths are made of equal lengths.
Add intake temps and intercooler positioning and there ain't a lot of choice.
Besides, it's right in your face when you open the decklid -which I kinda like!
The up-pipe I have constructed on-the-cheap for now, utilising some of the old scoob exhaust parts and much butchery. It'll do for now though while things are in the experimental stage.
And the bracket to mount the turbo in three pieces which uses the same mounting bolts to the turbo flange as subaru intended. Nice and sturdy once fitted
Both covered with lashings of VHT paint, and bolted in place...
... Only to be taken out again to sort out that nasty yellow stuff in the engine bay and fit the fuel tank etc.
More soon -cooling sys? fuel sys? wiring? so little time, so much to do
Joined: 09 Feb 2006 Posts: 778 Location: newmarket
Posted: Sun Oct 29, 2006 8:53 am Post subject: Re: Eine kleine turbo
smyell wrote:
Ok, update time. Finally a few days off work Also to be considered is the heat produced by the turbo itself. In it's standard position the turbo is very close to no.3 cylinder on an impreza, and the heat in some extreme cases have caused problems with overheating. Always the cylinder nearest the turbo that goes first from what i've read and heard. So I've kept a good clearance.
the main problem on all ej engines is that no3 is the last cylinder to get fuel ,this can be dealt with by feeding all the cylinders at the same time with parallel fuel lines . i have a link with pics somewhere i`ll post it when i find it _________________ vwdrc class rep
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