2270cc type 4 EFI Turbo: my first engine build

[split1950]

Yeah I was unsure if I need the fans, but I thought better safe than sorry. I'm running a thermostatic oil filter head so shouldn't over cool it.
I don't really know about fluid dynamics I'm not that kind of Engineer, I tried to find a balance between airflow and risk of it getting ripped off on our terrible British roads lol. So that was my guesstimate of the right height
I still have to mount a header tank, pump & radiator for the chargecooler, make a breather box that doesn't look rubbish, make (?) and mount a swirl pot with a pre pump & my 044 Bosch pump (maybe in the spare wheel well?) and make the post turbo / muffler system.
All the other stuff should be easy enough......yeah right!

[buguy]

I really like the detail and care your putting into that. It will show when your finished.

[split1950]

I have been busy in the garage, but not updated my thread on here for a while.
Made a new gearbox mount, drew it on CAD and had it laser cut and folded out of 4mm steel. Got some mounts off a V12 Ferrari, should be OK!

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Puts the gearbox +/-0.5mm of centre, good enough I guess
So I made some side tins (need to bend the side lips down but will do after the other pieces are made and bolted together. I made some nifty Aluminuim flat parts with M6 threads and my buddy Tig'd them onto the inlet manifolds as side tin mounts

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Rear tin is partially made, just need to cut it to follow the rear apron, trim the width and bend the lip down. It think I'll make the tin above the gearbox first.

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Exhaust header is done too, used flanges on the stub pipes for installation & removal, it is now +/- 10mm equal lengths (it's tacked and only needs purge welding...)

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Did a rough polish on it, I think it looks OK. I need to resist the temptation to go silly, I have enough other stuff to get finished.
Dry sump tank is mounted in a way that I'm now happy with, might remake the top bracket / something looking better with laser cutting.....oh dear I'll never learn....

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[panel]

That is some nice work there !

[buguy]

Very nice!

[split1950]

I'm getting there......
A few more tricky things to solve then hopefully I can get it into paint this summer

[split1950]

As I can't leave well enough alone, I beefed up the gearbox cradle as I'd had to cut quite a lot for those big engine mounts

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This pic is before I really tidied up the welds

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That's better and beefy. I can drop the cradle and change the 4 engine mounts with the engine and gearbox in place - I expect to rip a few mounts up if the engine works out as planned.

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Folded the lip on the side tins to give a ~12mm gap to the side trays on the body - this made them very stiff so I could also cut the big rear most tin ready for the lip on that after I solved the tin above the gearbox (not sure how to mount that.....). I'm going to make a nice Aluminium trim to go in the recess around the pully, nice and close - I wanted to be able to change the fan belt without drama.

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I guess I'll make some tabs.

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I'm planning on using the Beetle seal above the gearbox and along the side trays. I have the type 2 foam seal for the rear tin as there's nothing on the body - I'll have to fix that to the tin itself.
So one more design for the tin over the gearbox and a cardboard template to go...........(and weld that hole next to the starter gear from the previous gearbox mount idea that got binned!)

[buguy]

Well done. I'm getting ideas!

[split1950]

I decided to finish up completely on the engine mount, so that meant the engine support bar
This was a Type 2 Bay window bar that has been cut and modified for my car and to support the BW Turbo
I put these little circles on the ends for the engine mounts

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A nice bit of MiG welding

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In place on the car

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Got my local steel stockholder to cut and bend these 4mm mild steel plate mounts that bolt to the bumper mounts

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Final job is to make some long M10 female bolts to act as long nuts onto the engine mount threads (got some M10 threaded SS tube in the post and will weld an M10 SS washer and short bolt into the ends to do that).
Hopefully with 4 mounts horizontally and the 2 vertical mounts the engine and gearbox mount system should be well capable of handling the power. This is the first time I did anything like this.........time will tell!

[Bruce.m]

I’d add a triangular fillet to the right angle bender plate. Just welded in. Will make it much stronger.

[Ol'fogasaurus]

After over 35 years in aircraft engineering I had never heard of the "female bolt" so I looked it up.

It is a dual threaded bolt that is threaded on the outside and is hollow on the inside and threaded there. Not anything I would have been allowed to design to due to loading.

Thinking back about it I think I remember seeing one (many years ago) in use but it was used as a low load adapter. Be careful with it's use as I would expect it isn't that strong load wise especially "shear" wise.

Lee

[split1950]

The intention is it is smooth on the outside (OD13mm) with a M10 internal thread.
Would that still be too weak?
TBH I never thought of that......worst case I'll cut the cradle so the mount stud reaches through but it leaves nothing there either.
Unless I get a bigger OD female threaded tube....?

[split1950]

I’d add a triangular fillet to the right angle bender plate. Just welded in. Will make it much stronger.

Yeah to be honest I was wondering about that (there's a mirror image plate on the left bumper mount too) so your comment has made my mind up for me, I'll do that.
I think I may also "box in" that corner you can just see in the gearbox cradle picture above as it would be the same issue.

[Ol'fogasaurus]

If I remember correctly the ones I saw had the internal hole clear through and threaded the whole way. The insert acts as not only a clamping threaded bolt but as a doubler for the outer bolt (many, many years ago I saw this) hollow shank/fully threaded bolt. Again, since the outer bolt is compromised as to strength (grade some where below grade 6 would be my guess) but I suspect the grade would be lower.

I tried to look the strength ratings up but saw none for "female bolts". There was talk about them but none about grades.

An interesting conversation!

Lee

[split1950]

OK, so I've revised the engine bar.
Now I can use the normal M10 nuts, it should be fine............

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Whilst I was "in there" I added these fillets to the gearbox cradle to stiffen it

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I've decided to leave some flex on the parts that bolt to the bumper mounts because they are only spot welded on and if they rip off it will be expensive for paint etc

Thanks Lee for the advice on the shear of those stupid female bolts I made previously!! It seemed like a good idea at the time.