1987 GLHS#0896 Project log - Page 11 - Turbo Dodge Forums : Turbo Dodge Forum for Turbo Mopars, Shelbys, Dodge Daytona, Dodge SRT-4, Chrysler PT Cruiser, Omni and more!
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post #151 of 465 Old 06-23-2014, 08:40 AM Thread Starter
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Re: 1987 GLHS#0896 Project log

6-23-2014
OK, back to the turbo work for a minute.
(Actually, a couple days of porting/finishing work on the Turbine housing)

Here's a couple pics that I posted above, but didn't really describe well:
After sandblasting the Turbine housing,
I prepped it with wax & grease remover(paint prep),
and then used the 2000 protection primer & paint and baked it in my gas grill(as per the instructions).
Here's how it turned out:





Having barely touched the WG port, or the exhaust chambers yet,
there was some tinkering with different tools to see what would work best for it.
The final decision was to buy a 6", canister type porting bit for the die grinder and go to town.
(I opted out of the reamer bit pictured a few posts ago for the WG port)

I'll try to cover this process the best I can here.
The flange is indeed a T3 flange.
However, as you can see, it's not "up to par" for performance.
Tracing the inside of the gasket, you see the amount that must go:


So, I got my grinder, porting bit, and a bowl to catch the metal dust,
and I began to port it out:


I found that working in one area, using constant movement, and allowing THE TOOL to do the work, is best.
So, I began on the side with the 9 cast into it(9cm housing):








After I got it close, I experimented with a sanding drum in my Dremel tool:
(Came out really nice, and I made the decision to use this method for the finishing)


Then I moved on to the other side of the flange,
and began cutting gradually out to the outer traced line.
(The angle you cut at, at this point is irrelevant. the idea is to get out to the edge and match the port.
then afterwards, the finishing, smoothing can be done)
:




After smoothing in the edge and sanding with the Dremel,
it looks something like this:


With the gasket:


WG port lighted:


I'll have to update the WG port work, but that came out well too.
What I did there was used the same 6" bit, and kept checking the port with this 18mm socket that measures 25.88mm(about 1.02")


I'll get the details of that work up here soon.
Thanks again for checking in.

Best wishes everyone!

GLHS#0896
Under Construction

View the project log----------->1987 GLHS#0896 Project log<----------View the project log
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post #152 of 465 Old 06-23-2014, 08:56 AM
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Re: 1987 GLHS#0896 Project log

That's some purdy work Donnie
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post #153 of 465 Old 06-23-2014, 09:09 AM Thread Starter
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Re: 1987 GLHS#0896 Project log

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Originally Posted by ILIKESHELBYS View Post
That's some purdy work Donnie
Thanks Steve.
It's not as difficult as one might expect.
The key I've found with porting work is to allow the tool to do the work.
Years ago, when I first began porting parts, I would force the bit into the metal.lol
The bits would end up smoother than the ported parts!

Now there's obviously some pressure applied, but not nearly as much as might be assumed.
These bits(the good ones anyway) do a tremendous job.
Take your time, and the port will come out ab-SOL-utely beautiful.
Patience, and thoroughness are KEY.

Also, a "headlight"(basically a light that is attached to a headband) is a fantastic tool to use during this process.
They're definitely affordable at around $5!!!
Worth every penny.

Five LED Magnetic Head Lamp

GLHS#0896
Under Construction

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post #154 of 465 Old 06-23-2014, 09:48 PM Thread Starter
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Re: 1987 GLHS#0896 Project log

The WG port was a lot simpler to open up than I thought it would be.
(That is, once I got the proper bit to do the job)

I basically used an 18mm, 1/2" drive, deep socket as my "guide" lol
Once the port was big enough for the 25.88mm(total outside diameter) socket to slip into, I was good to go.

And, Here's a bit of CHRA work from days ago as well as today:
First, the sandblasting procedure.
I ran a long bolt with a washer through the center, with a washer and nut on the other side;
effectively preventing blast media from entering the center.
And clamped on a huge C-clamp to block the oiling holes.
Then, it went into the cabinet:

It probably goes without saying, but in my small blast cabinet, this huge clamp was a PITA!
So, eventually, I removed it and the bolt, nut and washers,
and just blasted the entire thing.

Then, I masked off the oiling holes and also the turbine & compressor sides of the CHRA before paint.


Then came this 2000 primer & paint, that I highly recommend.
(Held a torch to it afterwards, and it held up just fine)


Baked on the 2000 primer & paint in the gas grill.
(There's a 3 step process outlined on the can for best results)
(It may appear to be sitting right on the greasy grill, but it's set-up on a 2" length of exhaust pipe)


After the coating process was finished, and 24hrs had elapsed,
I began to remove any flaws in the CHRA.
Mostly the casting imperfections on the Turbine side:
Before:


During:


Completed:


The compressor housing will probably be enough to start a completely separate thread for!!! lol
But I'll try to keep it detailed, yet no so damn long. lol

Thanks again for checkin' in!

Next up: Header flanges to be modified.
The ChryCo flange must become a T3 flange;
And the header flange holes all require quite a bit of massaging. lol

Stay tuned!

GLHS#0896
Under Construction

View the project log----------->1987 GLHS#0896 Project log<----------View the project log

Last edited by signsoflife22; 06-25-2014 at 05:11 PM.
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post #155 of 465 Old 06-23-2014, 10:39 PM
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Re: 1987 GLHS#0896 Project log

wow that is might shiny in there...
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post #156 of 465 Old 06-24-2014, 07:30 AM Thread Starter
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Re: 1987 GLHS#0896 Project log

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Originally Posted by acannell View Post
wow that is might shiny in there...
Smooth is the goal. Shiny is the temporary side-effect. lol

Thanks Asa.
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post #157 of 465 Old 06-26-2014, 03:40 PM Thread Starter
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Re: 1987 GLHS#0896 Project log

6-26-2014
I couldn't resist; had to mock it up just once.


Probably could've done without the 351's elbow,
but it'll surely make for some interesting intercooler plumbing.

Now that I have seen exactly where it'll be positioned,
I have a better idea of the plumbing route I may take.

Thankfully, the header all but SOLVED the P/S pump clearance issue I would have faced with the downpipe on a factory mani.
(I may actually be able to use the factory HOLSET elbow)


This is a mock-up, non-CB, and a throw away 782 head.
Nice parts to have laying around for this very instance.

I took a measurement of the HE351's depth toward the firewall.
It's almost exactly 14" from the mounting surface of the head.

If anyone has an "L" body, and a few minutes,
it would be great to know the measurement from the Intake/Exhaust manifold mounting surface on the head, to the firewall.


Thank you, in advance for this info.

BTW: Still working on the porting and polishing of the header.
it's a TON of work, but not beyond the average skill level.
Thus-far, it's coming out fan-tas-tic!

Later!

GLHS#0896
Under Construction

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post #158 of 465 Old 06-26-2014, 04:43 PM
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Re: 1987 GLHS#0896 Project log

Lookin Good! Nice to see you taking your time and doing the same things I did to my HE351 before putting it on for good.

I had to massage the firewall back 1/4-1/2" with a rubber mallet to clear the HE351 with stock ported exhaust mani. Hopefully your header does Not make it any tighter.
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post #159 of 465 Old 06-26-2014, 05:11 PM Thread Starter
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Re: 1987 GLHS#0896 Project log

Quote:
Originally Posted by Shadow View Post
Lookin Good! Nice to see you taking your time and doing the same things I did to my HE351 before putting it on for good.

I had to massage the firewall back 1/4-1/2" with a rubber mallet to clear the HE351 with stock ported exhaust mani. Hopefully your header does Not make it any tighter.
Thanks Rob, I appreciate it.

Yeah, it may just fit, but it'll be SO close that eventually it'll begin to rub and tap the firewall.
But, I have the entire interior out of it now,
so a massage wouldn't really be much of a big deal.
I'll be installing a NON-A/C heater box.
I just hope that this "massaging" I'll do for clearance doesn't cause any issues there.
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post #160 of 465 Old 06-26-2014, 08:25 PM
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Re: 1987 GLHS#0896 Project log

I took a quick measurement on my car and its about 9 inches from the manifold mounting surface to the firewall. It would take a mighty big hammer to make that turbo fit in my engine compartment lol.
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post #161 of 465 Old 06-26-2014, 08:28 PM
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Re: 1987 GLHS#0896 Project log

couldn't resist mocking it up ...

lol
THAT would live front N center on my coffie table until it was ready for the car

!!
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post #162 of 465 Old 06-26-2014, 09:08 PM Thread Starter
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Re: 1987 GLHS#0896 Project log

Quote:
Originally Posted by RGL10 View Post
I took a quick measurement on my car and its about 9 inches from the manifold mounting surface to the firewall. It would take a mighty big hammer to make that turbo fit in my engine compartment lol.
SON-OF_A!!!!! That's a tight area.
Man I sure hope the 2dr has a bit more "room to move" in there.
9 inches! YOW; that blew my mind just now.
I'm now even dumber, and even MORE FULLsignsoflife

Quote:
Originally Posted by Dr. Johny Dodge View Post
couldn't resist mocking it up ...

lol
THAT would live front N center on my coffie table until it was ready for the car

!!
Damn Doc, if Randy's measurements match the 2dr's,
it may end up on my coffee table for good.

I gotta go lay down for a while. lol
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post #163 of 465 Old 06-26-2014, 09:18 PM
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Re: 1987 GLHS#0896 Project log

Quote:
Originally Posted by RGL10 View Post
I took a quick measurement on my car and its about 9 inches from the manifold mounting surface to the firewall. It would take a mighty big hammer to make that turbo fit in my engine compartment lol.
Could you please tell me where and how you measured from exactly? I've been trying to get an accurate measurement for the L-body "behind engine" zone for my custom intake.

SOL22: I may be able to help you with determining clearance somehow before you actually install it, if that would be useful. If RGL10 tells me the distance from the head gasket surface to the firewall, and you tell me some measurements of your turbo, I can draw it up in my SW model and post up the results here.

RGL10: Heres my side view model of the engine bay in a G body..could you point out what distance you measured? The vertical dotted line is the firewall. As you can see the firewall and the head gasket surface are not parallel so it makes a difference where along the surfaces you made the measurement and also the angle of the measurement line relative to both.

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post #164 of 465 Old 06-26-2014, 11:01 PM
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Re: 1987 GLHS#0896 Project log

My measurement is a little higher up than your arrows. I did my best to measure at the top of the intake gasket and hold it level to the firewall. This was on the transmission end of the head. I have a lot of stuff in the way but that should be within a quarter of an inch or so.
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post #165 of 465 Old 06-26-2014, 11:04 PM
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Re: 1987 GLHS#0896 Project log

Just took a measurement on the Charger and I get about 9 3/4- 10" from the firewall straight across to the edge of the head where you have your tape in your pic.

Remember now, that will be the tightest area because the motor is mounted on a slight angle. Having said that, I don't think your going to find an extra 4"s, prob more like 1-2" at best.
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