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I think I'd get a whole new one made that ran from TC to binnacle (rather than buying a new one or a blue box version).Quote:
Originally Posted by stirlsilver
Damn scary :no2:Quote:
Originally Posted by stirlsilver
I think I'd be checking the other side.
Hello again everyone, so I had my cousin Angus from Scotland come and give me a hand. He arrived in to Australia last week for a one year holiday and was keen to spend some time working on the car.
We managed to cobble a little bit of video footage before I ran out of battery. But at least you will get the idea!
[ame]https://youtu.be/VYpqbTRucl4[/ame]
The end of the day results, the first time Angus had ever been involved in tuning an engine!
https://www.aulro.com/afvb/images/im...016/02/968.jpg
Below is a screen shot of the changes done to the fuelling table. You can see how the tuning process is pulling the fuelling amounts right down. I need to do some extra tweaking to the table since I realized the table isn't setup quite right for the area on boost (manifold pressure greater than 100kPa). Anyway, exciting times!
https://www.aulro.com/afvb/images/im...016/02/969.jpg
Despite all the driving around, I found that the engine oil temperature sensor on the oil cooler didn't indicate above 31degC. Thinking that something wasn't right I went to investigate.
I ended up figuring out that I had put the oil fittings on the wrong way around, so the internal passage direct from the pump to the filter wasn't blocked off to force oil to the cooler.
Below is where I had the fitting with the internal oil seal which is wrong because the internal o-ring didn't seal against anything.
https://www.aulro.com/afvb/images/im...016/02/970.jpg
Pulling the oil filter off and all was revealed, it was clear where the internal o-ring was supposed to go.
https://www.aulro.com/afvb/images/im...016/02/971.jpg
The pipes was cut and the fittings swapped over and finally it should all work as intended now!
https://www.aulro.com/afvb/images/im...016/02/972.jpg
https://www.aulro.com/afvb/images/im...016/02/973.jpg
Another update on the job.
I got fed up with the squealing power steering bearing (I'm 80% sure it is the power steering pump and not the water pump) so I decided to pull the pump out so that it can be sent off to be re-built. The unit is a Hobourn 5503/8518/24 which after some research looks like it comes from some of the 1985 Range Rover. I think Hobourn is now looked after by Eaton, so hopefully it won't be too difficult to find someone to rebuild the unit.
https://www.aulro.com/afvb/images/im...016/02/974.jpg
Anyway, after that I moved on to preparing the bonnet for the intercooler scoop. To my absolute surprise the bonnet without ANY modification... SHUT!
https://www.aulro.com/afvb/images/im...016/02/975.jpg
https://www.aulro.com/afvb/images/im...016/02/976.jpg
Anyway, even thought everything fits under the bonnet, I need to make some holes. I used foam and some wet rags to mark the edges and center of the fan onto the underside.
https://www.aulro.com/afvb/images/im...016/02/977.jpg
Thanks to previous experience, I used the opportunity of a center point to mark circles in 5mm increments (from +10mm radius -10mm radius). That way if I need to go bigger after the first cut, I already have the lines drawn.
https://www.aulro.com/afvb/images/im...016/02/978.jpg
And the deed was done, in the end the smallest hole in my opinion suits well enough :D
https://www.aulro.com/afvb/images/im...016/02/979.jpg
https://www.aulro.com/afvb/images/im...016/02/980.jpg
Dont you just love when you get a good surprise like that (bonnet closing).
I like the wet rag trick! I'm going to remember that one.
Nice thread, only just got around to reading it!Quote:
Originally Posted by debruiser
Another trick I've used in the past is a blob of grease on one surface when there are tight tolerances, or a tower of Blu-Tac and a dab of paint on the top to mark heights / contact points between surfaces.
Keep up the good thread!
I hope you centred the holes to be simetrical about the centre line. It will look a bit cockeyed off centre.
Woudl be ok if he puts a scoop over the whole lot (as long as the scoop is center)Quote:
Originally Posted by slug_burner
Thats what I was thinking
Your snorkel looks to be a bit small and flexible!
Very interesting thread, have learned a few new tricks / ideas along the way.
The usual update again everyone. Though this one features some more SolidWorks stuff!
With the design of the air scoop, one thing that is important to me to to position it at a location where it will catch the air stream and thereby flow a lot more air through the intercooler cores. So in order to do that I had to do a Computational Fluid Dynamics (CFD) analysis. I traced out the profile of the car and used it to do a 2D analysis. I could have done it in 3D but it would have taken ages to solve and not provide that much more information.
Anyway, the GIF below is a nice summary of the results of how the pressure and flow changes as the car travels from 10km/h to 120km/h in 10km/h steps. If the image below doesn't animate you may need to click on it.
http://www.stirlsilver.com.au/images...pssmylck86.gif
When looking at the results, keep in mind that what it shows is how the air moves around the centreline of the car.
Here are some clearer snap shots, first one has pressure shown by the colour and the second shows velocity.
40Km/h
https://www.aulro.com/afvb/images/im...016/02/981.jpg
https://www.aulro.com/afvb/images/im...016/02/982.jpg
60Km/h
https://www.aulro.com/afvb/images/im...016/02/983.jpg
https://www.aulro.com/afvb/images/im...016/02/984.jpg
80Km/h
https://www.aulro.com/afvb/images/im...016/02/985.jpg
https://www.aulro.com/afvb/images/im...016/02/986.jpg
100Km/h
https://www.aulro.com/afvb/images/im...016/02/987.jpg
https://www.aulro.com/afvb/images/im...016/02/988.jpg
120Km/h
https://www.aulro.com/afvb/images/im...016/02/989.jpg
https://www.aulro.com/afvb/images/im...016/02/990.jpg
So what the above shows is that a ute creates massive amounts of turbulence behind it (surprise, surprise) a long time ago I had come up with a concept of putting a sloping canopy over the tray which should sort that out nicely. Anyway, the second thing is that, there seems to be a nice spot to catch the air flow as it goes over the bonnet and before it separates due to the windshield.
The area I am talking about is here.
https://www.aulro.com/afvb/images/im...016/02/991.jpg
So now that I know where is a likely place to catch the air stream, the next thing for me to do is start trialing different scoop designs to see which generates the most pressure across the intercooler cores. That will be something I need to do next.
So on other news. As I mentioned in the previous post, I had the power steering pump re-built due to the squealing bearing. While I had the pump out, I wanted to sort out a proper hose connector for it, as I was using an aluminium air conditioning fitting which sort of worked (it had a slight weep). I took the pump to Pirtek only to discover that they didn't have any fittings to suit. The Range Rover pump has a SAE-9 fitting (I think that is what it was) but it needed to have a male thread and a female flare, which they didn't have...
I gave up on that and simply simply did some modifications the aluminium fitting I had and managed to get it to seal. It's not the right thing to do but I didn't have a choice.
The other item I worked on was trying to seal the gap between the intercooler thermo fans and the holes in the bonnet. A trip down to Clark Rubber and I ended up settling on the hot water insulation tubes which are nice and spongy and I think would be rated for high temperature exposure.
https://www.aulro.com/afvb/images/im...016/02/992.jpg
I simply glued them into a doughnut and I was surprised how well it worked!
https://www.aulro.com/afvb/images/im...016/02/993.jpg
https://www.aulro.com/afvb/images/im...016/02/994.jpg
https://www.aulro.com/afvb/images/im...016/02/995.jpg
https://www.aulro.com/afvb/images/im...016/02/996.jpg
A bit more road tuning was done on the car, I have shown an extract of the engine log below where I got the manifold pressure to 140kPa (about 6psi of boost). This was achieved at 2500rpm and the throttle only partly open (I haven't dared put my foot to the floor yet).
https://www.aulro.com/afvb/images/im...016/02/997.jpg
All in all going well, the air temperature in the manifold didn't go beyond 44degC, but that was just on short runs. It will be interesting to see how well the intercoolers work under constant turbo boost.
Next step is driving the car to get the LPG hooked up (I go through a 9Kg bottle in no time!). You might spot me on the road this week if you live in the NSW hills area :)