RSB - 244 K-Jet Turbo Daily Driver

jlfents · 2016-10-26T00:19:56+00:00

Wheels come up nice. Just for future reference, if you ever way to do this again. Get them hydroblasted. It wont damage the surface and leaves them ultra c...

Vee_Que

Looking good!

alphax

Great work, looks like many hours of thinking and execution in this!

jlfents

Apologies for the delay. Thanks for the kind words!

@timbo The ratchet straps are the finishing touch!

@Ex850R You are right the welds are quite boogery. I bought a mig at the end of last year and had only FINISHED one other project before I started the exhaust so to say I’m inexperienced would be an understatement. There are no leaks from what I can hear, but once I get the car driving again I will do a once over and double check everything. There is a problem however, but I’ll explain this down the page.

@Dauntless I’ve put an A cam in there for now. And that is a cat, 200 cell I believe.

Engine/Drivetrain:
Not much is changed or new from the last update. Using a flat flywheel with 9” pressure plate and Volvo disc. Turbo is a Mamba GTX2871R. The manifold I ported myself and sent away for surfacing and cracks welded up.

Fuel:
I rebuilt the distributor and WUR myself. At first I used the original injectors from my B23E only because they are clean and spray well enough. However I am suffering from a fuel issue. During the first few drives I tuned to have a dead rich idle, and even then could only rev to 3k before leaning out. I have now switched over to the B21ET injectors, and along with resetting the CPR pressures this should fix my issue.

Ignition:
Using a programmable 123 Ignition distributor with a Bosch Blue coil. I loaded a copy of a B230f ignition curve just to cruise around for the first drives, so a proper tune still needs to happen. I’ll add it is open wastegate atm.

Wiring:
I bought a spare chassis/dash harness from another k-jet car and modified it on the ground. Any wiring associated with unused accessories was removed, things like headlight wipers etc. The headlight circuit was completely rewired with thick gauge wire and I updated to the Daniel Stern style circuit with relays. The ignition power was altered to run with the 123 distributor and send 12V straight to the coil. All of the new sensors are tucked into the harness too. Now everything is tidy, looks oem and in good condition.

Misc:
My old radiator was severely clogged and in bad condition. So bought an ebay aluminium drop-in replacement. Pretty good quality, looks nice. I wasn’t aware how far forward the intercooler pushes the radiator towards the engine. I couldn’t even fit the clutch fan back in let alone the shroud. So bought a 940/850 electric fan and put it in the 740 turbo shroud. Am still yet to wire up the full relay circuit.

Exhaust:
The system is 3” turbo back, cat and muffler, over the axle. Boy the downpipe really is tight. There is a finger space clearance between the pipe and steering column, but with a ratchet strap pulling the motor over a little bit it’s got ok room. However I assume an engineer won’t pass with a ratchet strap holding the engine so I think I will have to modify. Trouble is with the turbo outlet – the turbine housing has this weird Nissan style 6 bolt flange. With my limited skills I’m not able to fabricate something to follow that flange shape and transition into a standard pipe. So I bought this cast adapter piece that outlets to 3” at the steering column, hence why it’s so tight. I’m not sure what I’ll do yet, I might even look into making my own manifold to push the turbo forward, even if it’s just a log style.
The section behind the diff between the fuel tank and boot butt cheek is too tight as well, with some contact happening at idle. So will need to redo that piece as well as decide what I want to do with the tail exit style wise.

As I mentioned a freeze plug leaks badly. I will be ordering some plugs and gaskets tomorrow from fcp, but until I get this fixed the car is undrivable.

Other things that I still need to complete include install the oil cooler setup I have, finishing touches on wiring, mount the radiator properly, heatshield the brake lines, get a power steering pump in there, catch can, and finally engineers approval and register.

carnut222

carnut222;c-141145 wrote
jlfents;c-141132 wroteI looked into lh 2.2 ezk as you previously mentioned it might work. It is still an option though I will have to buy all the gear, and I see that as funds towards the 123 anyway.

I have that shroud, but I have heard 740 fan shrouds don't work with 240 because the centre's don't line up?
My dad used a 740T shroud on his 240 turbo conversion. I think it works fine...maybe a tiny bit of tweaking??

I was just re-reading this thread and realised I made an error commenting about the 740T fan shroud. On my dad’s turbo conversion, he did use a 740T (actually 780T - but same) however he deleted the mechanical fan and replaced it with an electric fan mounted to the shroud...so the misalignment was not an issue.

Great thread!

Vee_Que

Love it. How does the clutch feel? Is it the mamba adaptor you've used?

Dauntless

jlfents;c-155751 wrote@Dauntless I’ve put an A cam in there for now. And that is a cat, 200 cell I believe.

Cheers for the info. If the engine and car are both pre 1986, there's no legal requirement for a cat, is there?

The A cam is quite mild, so you should see some nice gains if you plan to upgrade that later.

jlfents

@Vee_Que The clutch is great. It is much lighter than the b23e clutch, much much lighter. I originally thought I hadn't bled properly so did the whole procedure multiple times. But no it's just light...

Yeah it's the mamba adaptor. It's specified as stainless cast. Is it suppose to rust?

@Dauntless Regarding the cat - I thought so too. When I spoke to the engineer I was going through what I wanted to do. He interrupted me and said that's all fine, he just wants it to have a cat. So not sure, but it has a cat now.

For starters I have the K cam from the b23e, but before I worry about any of that I need it to run and pass certification. I guess things will me optimised and upgraded in due time as with any project car.

ANDYPALM

Really want a set of those wheels, love the build

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