Stirlsilver's Disco Ute Project

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Originally Posted by slug_burner

I take it you do have a plenum that you will feed the outlet of the coolers into.

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I don't understand what you mean?? The cores feed into the plenum shown in the diagram? What I have to design now is the round to rectangular transition that will sit between the throttle body and the cores.

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Originally Posted by disco man

Sounds wicked mate!! i have seen one in Canada when i was working there. Man did it look TUFF old mate filled it with up LS1 chevy. big wheels big lift and all the toys custom steel tray with the timber deck boards. it really stood out against the big chev, ford, dodge, trucks that the north americans love. would love one myself. hope it goes well mate!!!

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Thanks Disco man! I appreciate the feedback.

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Originally Posted by Wicks89

There are so many unbelievable builds on this forum but this is just..... Off the bloody wall! Looks awesome mate! Can't wait to see this thing rolling around!

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Thanks Wicks! Your words really help with the motivation on the build!

OK, for the progress update.

I found a better way to route the right hand dump pipe - I wasn't happy with the fact that it would run between the axle and the engine mount:
https://www.aulro.com/afvb/images/im...14/03/1149.jpg

All the exhaust bits I needed were in my hands, so let the fun begin!:
https://www.aulro.com/afvb/images/im...14/03/1150.jpg

First up was making the collectors which would be welded to the manifold flanges. This is what I knocked up out of 10mm steel to cold work tube into the shape I needed. Unfortunately I didn't have access to Oxy & Acetylene so I had to rely on brute force:
https://www.aulro.com/afvb/images/im...14/03/1151.jpg

https://www.aulro.com/afvb/images/im...14/03/1152.jpg

This was the result. Not too bad considering it was done with a dirty big mallet:
https://www.aulro.com/afvb/images/im...14/03/1153.jpg

https://www.aulro.com/afvb/images/im...14/03/1154.jpg

And the various bits all welded together:
https://www.aulro.com/afvb/images/im...14/03/1155.jpg

Next up, positioning the left hand turbo where I wanted it. I suspended it off a tube with some steel wire and got to welding up the first tube run to it:
https://www.aulro.com/afvb/images/im...14/03/1156.jpg

https://www.aulro.com/afvb/images/im...14/03/1157.jpg

https://www.aulro.com/afvb/images/im...14/03/1158.jpg

The first run with the turbo flange tacked in position:
https://www.aulro.com/afvb/images/im...14/03/1159.jpg

Once the first run was done, I no longer needed to do the work on the car so I move to a spare engine I had do the other runs:
https://www.aulro.com/afvb/images/im...14/03/1160.jpg

Splicing two elbows together:
https://www.aulro.com/afvb/images/im...14/03/1161.jpg

The second run done:
https://www.aulro.com/afvb/images/im...14/03/1162.jpg

https://www.aulro.com/afvb/images/im...14/03/1163.jpg

Progress is a lot slower than I expected, I should be quicker on the other side as I learn the best way to do things.

That's it for the week.

Looking great mate ;) I just love this thread :D

That's looking awesome, I don't know if you have already covered it, but I've tried reading through it all but I may have missed some.

Why are you going for such a large Plenum?

Is that going to be any advantage over just running the large intercooler into a normal sized plenum just to allow room to balance any pressure differences?

Seems your running injected LPG and forced induction, I didn't think the plenum would need to be so large.

Again, I may have missed something, I was reading some of it late at night trying to catch up and I'm thinking that some of it didn't sink in lol

Hahaha, I get it now, the trick is don't read things at night when your not retaining anything properly.

I'd see the pics of the plenum with the intercoolers connected and it was in my head that it was just a huge plenum chamber and was scratching my head why, not even thinking to ask the question.

I've now jumped about 3 pages to the turbo fit and missed where that was the intercoolers, i thought the intercooler was going in front of the radiator between the air con condenser for some reason.

Probably cross information from what i was reading that night while having an attack of insomnia hahaha.

Sorry mate, Ignore the above post, I'm an idiot. hahaha.

Hi mate - looking good. Quick question about the 8 exhaust flange plate thingys you have had made - I am looking for a set of these myself at some stage as I want to make a new set of manifolds for the 101 when time permits. Did you have these made by someone or have access to the required equipment yourself?

If you had them made, who did them and do they still have the drawing for them? It would save me having to start from scratch.

Cheers - Gav

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Originally Posted by rangieman

Looking great mate ;) I just love this thread :D

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Thanks Chris!! I hope all is going well on your end mate!

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Originally Posted by Casper

Hahaha, I get it now, the trick is don't read things at night when your not retaining anything properly.

I'd see the pics of the plenum with the intercoolers connected and it was in my head that it was just a huge plenum chamber and was scratching my head why, not even thinking to ask the question.

I've now jumped about 3 pages to the turbo fit and missed where that was the intercoolers, i thought the intercooler was going in front of the radiator between the air con condenser for some reason.

Probably cross information from what i was reading that night while having an attack of insomnia hahaha.

Sorry mate, Ignore the above post, I'm an idiot. hahaha.

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Glad you got it all sorted Casper! I'm going about it a bit of a different way, but i'm pretty sure it will work!

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Originally Posted by bacicat

Hi mate - looking good. Quick question about the 8 exhaust flange plate thingys you have had made - I am looking for a set of these myself at some stage as I want to make a new set of manifolds for the 101 when time permits. Did you have these made by someone or have access to the required equipment yourself?

If you had them made, who did them and do they still have the drawing for them? It would save me having to start from scratch.

Cheers - Gav

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Hi Gav,
I still have the drawings. If you want I can arrange a set for you if you like? If you agree to pay something it could be a small donation to the project :angel: The cost of a full set should be about $50 plus posting it out to you.

On to more important matters

I have accepted a new job in Sydney and I am basically going to be starting it in 2 weeks. As a result I need to move all my gear & the car to Sydney in the next couple of months.

Does anyone know of or have a location where I could house this build and continue working on it? Preferably somewhere near the Castle Hill?

So all those dots on the turbo are for photo-modelling?

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Originally Posted by Dougal

So all those dots on the turbo are for photo-modelling?

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I suspect that is the case. A lead on a good cheap program to process the images into a CAD format would be good.

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Originally Posted by stirlsilver

On to more important matters

I have accepted a new job in Sydney and I am basically going to be starting it in 2 weeks. As a result I need to move all my gear & the car to Sydney in the next couple of months.

Does anyone know of or have a location where I could house this build and continue working on it? Preferably somewhere near the Castle Hill?

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Wish I had the space at my place and work grumble when I have my Disco in the workshop for more than a few hours. I'm just down Pennant Hills Road, so let me know if you ever need a hand though.

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Originally Posted by Dougal

So all those dots on the turbo are for photo-modelling?

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Yes, that was the plan initially. I tried it but the software package which I had (I can't remember the name now) couldn't handle so many points. So I gave up and just did a basic model based on some photos directly in SolidWorks.

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Originally Posted by Tyresqueal

Wish I had the space at my place and work grumble when I have my Disco in the workshop for more than a few hours. I'm just down Pennant Hills Road, so let me know if you ever need a hand though.

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Thanks for the offer, it's appreciated. I have a couple of months to sort something out up there, but I will be starting to work in Castle Hill from the 17th of March and will then be flying back and forth to Melbourne to tie up all loose ends. Hectic times. If you hear of anything coming up, drop me a line!

I spent a little bit more time tonight on the intake design. Unfortunately the brake master cylinder is in the way, so I've had to make a compromise on the right hand intercooler inlet tank.

https://www.aulro.com/afvb/images/im...14/03/1036.jpg

https://www.aulro.com/afvb/images/im...14/03/1037.jpg