Tom
Chats A Bit
Posts: 218 
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Post by Tom on Dec 8, 2016 13:03:03 GMT
Looking good! Have to say as impressive as (some) FI'd 5's are, ITBs are properly addictive! One of the things I'm looking at on my setup is the length of the trumpets. Seems some of the guys in the states have founs significant gains by using longer setups. For example the standard Jenvey 50mm trumpets are allegedly not really optimal length - apparently suitaed to somewhere in the 8500-9000rpm range. Big gains apparently reported with 90-110mm trumpets that bring the harmonics down to a more useable rev range. What sort of cost is it for you to print these? Seems there's not many off the shelf options out there, especially in 42mm dia size! Thats what I like so much about the prospect of printing the trumpets, knocking up different lengths is a breeze and not too expensive! The cost is dependant on material, I have a carbon fibre infused polymer which I am going to use for the centre sections as its stiff and has a good resistance to moderate temperatures. The trumpets I think can be made of cheaper materials (even the carbon stuff is only ~£50 per kilo) Either ABS or perhaps even PLA. It depends on the ambient temp reached in the bay when staitionary. I think per trumpet+adaptor at a total guess perhaps a couple of quid.. A bit of rubbing with some wet and dry leaves them very smooth inside. The TBs I have got are off a tt600 so I think they are actually slightly larger on the ID (45mm) than the 42mm used by jenvey and the seemingly fairly go to GSXR750 bodies, not sure how this will effect things, but its not too hard to adapt the kit to different dimensions for other TBs. I like the fact I can split all of these and equally space them rather than the GSXRs which are cast into pairs. Just wish I had a 1.8 engine as getting the injectors mounted is going to be a royal PITA! I was considering using the TB injector ports but I'm not keen on blowing petrol through a plastic tube, not to mention the more direct the squirt to the valve the better as far as I can tell. |
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Tom
Chats A Bit
Posts: 218
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Post by Tom on Dec 10, 2016 23:43:47 GMT
Printed and fitting a treat! Just need to trim the bolts down somewhat!  Made my own seals  This came out really nicely though it highlighted some changes that were needed, note the hacked up inlet in the parts washer/sink behind!  All together.  Getting there, need to experiment with materials now. |
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Tom
Chats A Bit
Posts: 218
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Post by Tom on Apr 10, 2017 9:30:02 GMT
No updates in forever!
Still not fitted my ITBS, nearly sold the car. Went out to fix it ready for sale, drove it briefly and took the add down...
ITBs will be on soon, decided against the 3d printed lowers, not happy with the likely heat transfer, so trumpets only. Currently spending some time trying to CAD up some wedge shaped flanges to get a 20 degree tilt on them using the standard tt600 mounting boots I have sourced.
Car is running the best it has in a very long time though, and the combo of light flywheel, no turbo, proper manifold makes for some cool noises- no doubt only to be improved by the ITBS.
Spent quite a while rectifying birds nests behind the dash and putting the interior back together, looks quite civilised inside now. Will stick up some pics later on.
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Post by baconsarnie on Apr 10, 2017 10:43:58 GMT
Stick with it, it'll be worth it! ITBs making the car an event to drive and make it an even bigger contrast to the modern machinery  |
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Post by trikkisixx on Apr 10, 2017 13:07:24 GMT
That is rather lovely! What's prompted the change from FI to ITB?
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Tom
Chats A Bit
Posts: 218
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Post by Tom on Apr 10, 2017 15:01:30 GMT
I just felt a bit frustrated driving it on the road with the turbo. Despite the torque low down from the turbo it wanted to be driven hard, and given the fairly sticky tyres punching out of corners left me at license endangering speeds very quickly.
It was an absolute hoot, but I think that being able to drive it flat out will be more fun on the road; of course it will still go "as fast" since the gearing is the same, but the extra time to get there means I can really put the pedal down- hopefully.
I've actually been really enjoying going back over the car recently, the turbo set up was all rushed in very quickly and going back and tidying up the wiring etc. is very satisfying!
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Post by trikkisixx on Apr 10, 2017 15:21:09 GMT
Fair play to you, it's all about driveability! Don't suppose you have any turbo bits kicking about still?  I can't wait to get all my turbo bits bolted up and get all of the bay nice and clean and tidy! |
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Tom
Chats A Bit
Posts: 218
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Post by Tom on Apr 26, 2017 13:43:21 GMT
Spent some time getting my sidelights and indicators back in for some OEM cool. Ran with the LEDs and did a little conversion. Indicator retains an OEM style 3D printed twist fitting. Sidelight wasn't quite big enough so after much consideration I split them and inserted it from the front. Didn't de-tango it as I quite like the orange!  |
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Tom
Chats A Bit
Posts: 218
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Post by Tom on Mar 18, 2019 12:11:13 GMT
Long overdue progress on this after sitting for a while. Housing etc. has meant a lack of progress, coupled with the purchase of a Cayman I left it alone for a while.. House upgrade means the Cayman must go and the mazda is back in favour..
I fitted my ITBs and almost instantly lost no.3... engine was not happy, suspected a headgasket failure a result of turbo-ing. Anyway once I got the head off it seemed all was actually well in that regard. However flipping the head over it was a different story, none of the valves looked to be seated great, no.3 particularly and there was carbon everywhere! A quick 40 thou skim and 3 angle valve job later it all looked much better.
I got my ITBs together and tarted them up a little bit:
Painted the cam cover and the exhaust manifold, and wrapped the latter-badly:
Head looks a little like this with the coolant re-route being installed at the same time:
Cams are currently off to Kent to have a 265 reprofile before I can stick it all back together properly.
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Post by josho on Mar 18, 2019 12:54:55 GMT
I like this a lot! So awesome.
Will keep an eye on how your trumpets stand up to the heat. Need to make some long ones for my build.
Can't wait to see this one up and running
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Post by Zed. on Mar 18, 2019 17:55:03 GMT
looking at the angles of the manifold / throttles & rampipes, hows it's fit in the car (brake servo / master cylinder clearance?) Rich. |
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Tom
Chats A Bit
Posts: 218
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Post by Tom on Mar 18, 2019 18:26:21 GMT
I like this a lot! So awesome. Will keep an eye on how your trumpets stand up to the heat. Need to make some long ones for my build. Can't wait to see this one up and running Cheers, it's printed in PETG currently which has a glass transition temp around 100 degrees, while the engine is running the airflow should keep them cool, so it's only the bay temp. after running, we'll see! I have a few other options to try, got some high temp nylon and I have access to peek as well, seems very unlikely to be necessary though. looking at the angles of the manifold / throttles & rampipes, hows it's fit in the car (brake servo / master cylinder clearance?) Rich. It's "snug"  |
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Post by Zed. on Mar 18, 2019 18:59:02 GMT
'Snug'  a case of "if I fits, I sits"  watching with intrest Rich. |
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Post by teamawesome on Mar 18, 2019 20:01:13 GMT
It's looking very good mate. Give us a shout when it's running, I'd like to see it. Mines changed a lot too....
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Post by atlex on Mar 18, 2019 21:50:54 GMT
You can move that brake distributor block out the way if you're prepared to redo the lines.
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le sigh