Don't know how I missed this thread, good work ?
R-Sport B21AT turbo build
So I tore down a mechanical fuel pump to see how difficult it would be to boost reference it, and basically I can't be bothered. The car already is plumbed for a return system as it's currently K-Jet, so I'm going to instead use a modern pressure regulator. I think I've settled on a Fuelab 515 which has a pretty nice range of adjustment and will not look too alien in my engine bay. This means the fuel tank and pump are all going to remain as-is, which is nice, as if I ever get over this setup I can go back to K-Jet with minimal hassle.
That aside, today I finished off assembly of the bottom end, barring a couple of fasteners and the oil pan, as I don't have any more M8x16 bolts. I'm waiting on a bunch of fresh fasteners.
I can't start work on the top end just yet, so I am next going to be looking at reproducing the original R-Sport oil cooler hardlines. This is what I have presently:
And this is what I need to end up with:
Other turbo redblock Volvos use a slightly different setup with hoses and hardlines in different places. The bracket you see in the photo above is the one from a 740 Turbo, GCP had them for sale for $not much, and comparing it to the diagram you can see that aside from the actual pipe clamp, it's the same part (the part numbers are different though). I can live with that!
So, I have braze-on banjos and fittings on their way to me from the UK. I have a pipe bending tool but all the same this is probably going to take me a few goes. I may also take this whole setup off the new engine and fit it to my existing engine as I need to make sure these pipes stay clear of the steering column.
Surely you can buy stuff here?
Id be going Festo and using clamp that has plastic blocks instead of bare metal but ey, this is more like the rest of the car.
Sticking foam on those clamps would be fine right?
egads (she/her)Sticking foam on those clamps would be fine right?
Foam isnt strong enough and the clamos i would use are for hydraulics so overkil....But kool....
Ex850RSurely you can buy stuff here?
Id be going Festo and using clamp that has plastic blocks instead of bare metal but ey, this is more like the rest of the car.
I did hunt around locally but had a hard time finding braze fittings.
I'm not sure why you would want foam or anything, these are steel pipes were talking about, once clamped they don't move.
Just thinking of heating and cooling cycles slowly doing them in but probably way overthinking it
Fasteners and banjos turned up. I'm going to try and see if I can use some steel tubing I already have, it has some bends in it already but I think they might actually match up pretty neatly with what I need, so hopefully that will save me some time/the need to buy more steel tube.
Okay so this is what I'm aiming for. I mocked it up with some old 740T hardlines. When I get a chance I'll tack everything together and then see if I can find a shop that can fab up fresh pipe to match.
Is it worth buying a reasonable tube bender?
If you have other use for it or others maybe?
I have a tube bender, but it can't do these kinds of tight radii, the smallest it can do is maybe a 50mm radius, these are about 30mm radius. Benders that can do those kinds of bends in steel pipe aren't cheap and honestly I have no need for one, if this was any other build I would just use aluminium hardlines and be happy with larger bend radii, but this build is all kinds of crazy attempts at reproducing the factory finish.
Okay mockup pipes are finished. Now to figure out how to make/have someone make the actual ones. Anyone have experience with this sort of thing?
Okay so I went down to Pirtek today and they can do 12mm steel pipe with a 38mm radius. The bends you see in these photos are about 30mm. They wanted about $80 for the two pipes so I left it with them to make a copy. The guy who does it will be in tomorrow, I asked him to give me a call beforehand and I'll see if he wants me to bring the block down so he has a fixture to work with.
It is amazing what those guys can do , ive seen (them (instrument fitters and the like) bend up a bit of wire of which goes which way , looks like an iso drawing , a few measurements and they come back with the spool and fit it off! .... you gave him an example to follow he will be fine.
Pirtek hooked me up. The last step is to braze the fittings on, another forum member has offered to help me with this.
Nizze. So shiny!
The clean sump pan bolts and a few others look like they've been zinc dipped.
That looks dead sexy !
- Edited
Major LedfootNizze. So shiny!
The clean sump pan bolts and a few others look like they've been zinc dipped.
Those are all new bolts, I'm missing a lot of fasteners for this block as it didn't come with that many to begin with and others I've stolen for other projects over the years.
That reminds me, I don't have head bolts! (Edit: actually I'm pretty sure I have a box of used head bolts somewhere...)