Cerberus Project

[vex]

Pulled a 24 hour shop night. Got a lot accomplished. Will post pictures later today.

[vex]

Well, here's the pictures. I spent all last night working on the car and getting the turbo manifold put together/mocked up. So I'll let the pictures speak for themselves.

After the primaries were welded up:

Notice that there is no room for the Wastegate runner to be mounted on top of the primaries:

So we put them on the bottom:




Making of the collector:




Well, I tacked the collector and the flange together and checked for interference and did a mock fitting:

[misthael]

I'm definitely not an expert, or anywhere near, as far as welding goes but those welds look really really good to me. Very clean. Nice build.

[vex]

Originally Posted by misthael

I'm definitely not an expert, or anywhere near, as far as welding goes but those welds look really really good to me. Very clean. Nice build.

The Joys of Tig. Honestly those were done by my friend who has a shop next door and his work is top notch. He's going to school to be a welder and is teaching me to use a Tig which by the way is TIG>>>>>>>>>>>>>>MIG. If you look closely at the collector portion of the manifold you'll see my handy work with the MIG (Flux Core). It looks like complete ass. But it was the best I could do at 6 AM.

Oh and TTT: I'm definitely going to put in the money for a miller tig. I'm hooked. Sooooo much easier than Flux Core, but can't fill the gaps I can with Flux core. But so much less clean up.

[vex]

Okay, quick update. There aren't many pictures right now because well... I've been stuck trying to get bluetooth to connect to my phone to transfer the files over. Sometimes it works, sometimes it doesn't.

Today I finished up the fuel system. My injectors are installed. 900cc/min primaries and 1360cc/min secondaries. I also finished up my fuel lines. Spent 60 bones getting some -6AN fittings to make everything work. It does, and looks half way decent. I also hacked up my AFM/throttle body pipe to connect to the turbo inlet and the AFM (Since RTek still haven't released the AFM delete yet) but in doing so doesn't leave much of any room to connect any sort of filter. I may have to figure something out but at least to drive it or start the break in process I can leave it as is. I also figured out the oil drain size and length I need, and have a few small details to work out. I also did the base hook up of both the EGT's and the Boost gauge. The EGT's have a weird hook up. You do not hook them up to an ignition source or 12v switched power like you do with the boost gauge, you actually hook them up to an always on 12v constant line. Apparently it knows when you turn the key on or off just by the voltage drop when you switch the car to acc.

What's still left for me to do is:
get BOV flange welded to charge piping.
finish exhaust
finish manifold
Finish wiring power to the ProSport gauges
finish wiring in the LC-1 (no need for an op-amp circuit, switch, etc--just won't be running NB)
hook up oil drain hose
install manifold
install oil injectors
prime engine
stab CAS (anyone want to offer the basic procedure to do that?--I think I know how, but just would like to be safe)
install 1.75-1.5 T fitting for radiator
prime fuel system
check for leaks
crank engine

Think I can get those done in a day? I think I can!

[WE3RX7]

Great progress man...

Honestly, the turbo looks tight but it also looks at home

Its hard to tell on the photos, but does it seem like you'll have any trouble with the downpipe clearing the actuators?

You can also dump the TID in front of the radiator if you dont mind a little cutting, etc. At least in there you may have more room for an air filter.


The CAS is simple, line up the marks on the pulles and line up the mark on the CAS body to the gear and you should be set. Provided you put the pulley on correctly

[vex]

Originally Posted by WE3RX7

Great progress man...

Honestly, the turbo looks tight but it also looks at home

Its hard to tell on the photos, but does it seem like you'll have any trouble with the downpipe clearing the actuators?

You can also dump the TID in front of the radiator if you dont mind a little cutting, etc. At least in there you may have more room for an air filter.


The CAS is simple, line up the marks on the pulles and line up the mark on the CAS body to the gear and you should be set. Provided you put the pulley on correctly

Pulley's on correctly... but I have two different colors/marks on the pulley (not on opposite ends mind you, but fairly close together). That's what I thought I needed to do, but wasn't sure. Now i have to figure out which mark is TDC and which one is not.

The down pipe clears the actuators without issue, but since my original plans called for the wastegate to be on top of the primaries I now have interference with where I would like to have mounted my wastegate. I'm just going to end up welding in an angle and mounting the wastegate that way and running an open dump... at least for awhile. As for the filter I don't mind running it infront of the radiator, but I don't exactly have a TID that has those bends. This is an NA tube that I hacked up. I may get lucky and find some 3inch pipe or something and just hook up some couplers to it--we'll see.

[WE3RX7]

Honestly, I have quite a bit of polished tubing, couplers, etc from my years of building IC pipes and CAI on my cars, lol... You're more than welcome to some of it if you need it. I think I actually have a 3" pipe somewhere, but most of its 2.25" (for a mazdaspeed protege).


As for those marks, you should have a yellow one and a red one right? Yellow is for leading, red is for trailing. Line the yellow one up w/ the pin on the front cover, then match up the CAS marks and drop it in.

[vex]

sweet. Thanks!

I would definitely appreciate a 3" tube if you have it. In the meantime I'm going to have to figure out how to route this bad boy so I don't run it on the road without a filter.

[vex]

Had to cut out of the garage early today to finish a project that is due in two hours (finished with two hours to spare ). In the hours that I did work at the garage I found out something interesting:

The ring on the hub for the pulleys is sort of important to keep the pulleys from being eccentric in orbit. I corrected it as best as I could (hacked an adapter pieces, shoved them together and wrapped with tape). The adapter sat inside the hub and was snug. The outside was larger and was snug on the pulleys. Hopefully this will be enough to not cause significant problems. It's about as good as it's going to get.

I was also able to build oil pressure and begin aluminum welding of the intercooler, charge piping, and a few other goodies. I hope to be done welding aluminum tomorrow and will hopefully have the entire exhaust done as well. Once those are all welded together I should be able to fill the tank with gas, top off the oil and coolant, and fire her up. All the gauges are installed and zeroed out. I'm getting exceptional close.

I still need to get an adapter piece for the radiator. I'm having a tremendous time trying to find a 1.5-1.75 inch adapter tee fitting with a 5/8in piece to hook in for the heater line.

If anyone knows of a location to get one hit it.

[vex]

It has started and runs! It purrs like an angry cat... well, that might just be because I don't have my exhaust finished. I still have a little work to do with the charge piping (so if you look closely you'll notice that I don't have a blow-off valve on that piping, and I couldn't shut the hood if I wanted to. It's temporary, i'm working on getting some aluminum pipe welded to ensure a tight fit).

[WE3RX7]

This is great man - cant wait to see the car again.


Go finish that fab work and bring it to culpeper

[vex]

Well, brought her home today on a rough tune. Had to richen it up alot which is surprising (or not if you think about it). I'm aiming for 12's which I'm pretty good at seeing right now. I start to get into the low to mid 13's which is kind of concerning to me, but will be taking care of that tomorrow. I hope to get my AFR datalogging troubles taken care of sooner rather than later to ensure tuning accuracy.

As for the exhaust note, it's louder than stock... that's for sure. But it's actually quite nice. Very deep, the higher the revs, the quieter it gets (3000rpm ceiling).

Had a bit of a scare when I first took her out: I was going up the hill near the shop and almost at the top the car just dies. No stumble, no stutter, just dies. Had power, could crank. It was interesting to say the least. So I back it down in neutral and I don't see any leaks, puddles, anything that would suggest something horrible, so I think about it for a few seconds and realize it sounds like a huge vacuum leak. Light bulb dings, I go off and start looking at all the couplers. I know I tightened all of them... except, one. It was the 90* coming off the turbo that slipped off. Easy fix, just popped it back on and tightened it up and I was good to go.

Still have a few things to figure out, but all in all it looks like this project is done until some later date (after I get hitched).

[WE3RX7]

Thats awesome man, really looking forward to seeing it (in the daylight) next time your in culpeper...

[vex]

Originally Posted by WE3RX7

Thats awesome man, really looking forward to seeing it (in the daylight) next time your in culpeper...

I should be up that way this weekend if everything goes as planned. You can point and laugh at my "air filter" and help me actually make a more permanent solution (if you have a 3" 90* bend, it would help out ALOT). I'll also need to pick up an adapter for the barn door since RTek still hasn't released their AFM delete yet.