Donations towards server fund so far this month.

 
£0.00 / £100.00 per month
Page:
Home > Show Us Yours! > K1100 turbo track car build - Clutch Issues

nky_84

User Avatar

218 Posts
Member #: 9213
Senior Member

Scotland

Med dog box, tranx plate type lsd and straight cut 4.5 cwp. Its an amazing setup for the sprints and hillclimbs that I do.

Ive been quoted 170+vat *frown* to do welding and machining. Going to try a few other places I think!


nky_84

User Avatar

218 Posts
Member #: 9213
Senior Member

Scotland

Double post.........

Edited by nky_84 on 19th Aug, 2014.


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Blimey that is expensive. I had a company quote me ú150+vat but i could tell they just didn't want the job to be honest.


On 19th Aug, 2014 nky_84 said:
Med dog box, tranx plate type lsd and straight cut 4.5 cwp. Its an amazing setup for the sprints and hillclimbs that I do.

Ive been quoted 170+vat *frown* to do welding and machining. Going to try a few other places I think!


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Bit of an update.

On the engine front I have now decided to sell the K1200 head an opt for a K1100 with the lower lift - shorter duration cams. I have picked up a couple of K1100 engines off a biker friend of mine and so one of these will be up for sale soon.

After eyeing up the possibility of making my own and making the decision between floor and bulkhead mounting solutions, Ive opted for a wilwood pedal box. Mounted up on two lengths of 1" OD CDS tubing and some 3mm fab'd brackets





I've also moved the seat mount locations back another 50mm to accomodate the new pedal box and steering wheel position with the new column mount.

I was unhappy with the column mount I had previously and also thought it best to have some adjustment in this area as things can seem lovely when it's all mocked up statically in the garage but then seem wrong when used in anger. This was the result




adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Bit of an update at last!

Finally got the shell to a condition ready for blasting so it was time to sort the trailer out. The 3mm steel load beds on it were shot to shit on each side with rot in a meter long section. That got cut out and replaced with new metal. Rewired and treated to some new wheel bearings and rubber blocks, she was like a new un'

A dolly was made to wheel the shell on/off the trailer as I didn't have anyone available to give me some muscle during the week. It worked a treat to shift it around the blasters and the garage

So off it went while I gave the garage a much needed tidy.







I'm chuffed with the finished job. It was carried out by Midlands surface finishing on Bayton road ind. estate in Coventry. Nice small family run, mother, father and son workforce who were more than happy to let me collect late on friday after they closed, so thumbs up there.

So the next task is to start welding the cage in. I've opted for a custom cages GPA clubman which I've trial fully fitted before the shell was blasted and all the tubes fillets and profiles appear to be cock on so I'd recommend them for certain.

To anyone else buying one of these cages (it isn't mentioned in the fitting guide) but you need to dress the inside top face of the A pillars back to allow clearance. I thought it was just a bad fitting cage at first but it was cleared up once I'd spoken to them over the phone.

edited: grammar

Edited by adcyork on 18th Dec, 2014.


apbellamy

User Avatar

16538 Posts
Member #: 4241
King Gaycharger, butt plug dealer, Sheldon Cooper and a BAC but generally a niceish fella if you dont mind a northerner

Rotherham, South Yorkshire

Looking good.

On 11th Feb, 2015 robert said:
i tried putting soap on it , and heating it to brown , then slathered my new lube on it

*hehe!*


Callum

449 Posts
Member #: 10396
Advanced Member Formerly mk2turbo

Stoke-on-Trent

Looking good, how much did they charge for the blasting?


jonny f

User Avatar

2027 Posts
Member #: 9894
Post Whore

Dorking

Looks great that!


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Cheers chaps. The blasting was ú500 total, which included blasting and red oxide spraying of the shell, subframes, all of the suspension components and a few other items.

They did the majority of the shell with chilled iron and then carefully used a garnet on the roof and other big panels to stop any warping which looks to have been avoided. We shall see when i start rubbing down for paint though. It is a little difficult to tell with the matt finish red oxide

Edited by adcyork on 18th Dec, 2014.


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Bit of an update.

After the shell came back from the blasters there was a few of the usual bits of rot around the top of the A post where the A panel meets it that were expected. That sorted, the new A panels were fitted and the passenger door re-skinned to correct some heavy damage caused in a car park a couple of years back. The door isn't shut all the way in the pic, the shut line isnt that bad! *happy*






The cage is now welded in minus the door bars which will be one the last jobs. No need to make it more awkward to get in than I must at this stage. Mocked up with tape, part welded, dropped down through the floor, final welding round the top of the tubes and bish bash bosh, in:







After much thought and deliberation over the design I put the miglia style rear ARB into production and got cracking with the turning and laser cutting. The bar is 18mm OD and the calcs have been run to give equal roll stiffness at the wheel compared to the 19mm underslung type bar sold by KAD, minispres, etc.

A tube was heavier for equivalent torsional stiffness in this application which had a knock on effect of having to enlarge the lever arms and bearing spigots to accommodate the larger tube and therefore adding further mass. A couple of spherical bearings in the end allow for any misalignment in the turrets.











Also, I've yet to tap specialist components up about this, but I acquired one of their manifold flanges and it seems not to line up with the K1100 manifold studs. The holes spacing is correct on both sides but the indexing between one side and the other is out by circa 4mm.

Anyone else found an issue?









matty

User Avatar

8297 Posts
Member #: 408
Turbo Love Palace Fool

Aylesbury

Yep I've got the same flange, and have the same issue. I'm sorting out getting some of my own cut today, as I've got my turbo manifolds all jigged up but no flange to weld it too. *oh well* The only way to sort it is to separate each pipe flange.

https://www.facebook.com/pages/Fusion-Fabri..._homepage_panel

www.fusionfabs.co.uk



1/4mile in 13.2sec @ 111 terminal on 15psi


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Since the last post a few key bit of progress have been made.

First off I've sorted the wiper motor relocation which wasn't anything like the nightmare task people make it out to be, the bulkhead hole just required slotting and a mount fab'ing up to use the standard clamp.



After much deliberation I have finalised the cooling system configuration.

I've got a cheap ali cored cinq rad which i've knocked an end tank up with the usual fun of bending in the vice over pieces of angle iron. I have moved the outlets so they exit at 90 deg to clear up a chunk of grill area. I had it welded on by Ady of Pristean Welding in coventry. He's a one man band affair who used to weld all the bottles for lifeline until recently going self employed. Hes very fairly priced, so I think he deserves a plug on here.

I've been considering what to do IC wise and I've decided on a side mount set up in place of the standard rad (Skyline R33/34 sort of size). With this in mind I've shifted all of the cooling gubbins over to the other side. The dry deck 'U' pipe will now go between the head/water pump plate at the front of the engine with the leccy pump, in-line thermostat etc mounted at the clutch end. The idea being that with the front end of the engine de-cluttered I can get a decent shape duct from the grill to the IC that will be mounted on the inner wing with a puller fan.









Next up it was time to make some proper swarf! I turned up a remote thermostat housing that uses a subaru justy thermostat as these are available in 82 and 88 deg temps and are 10mm smaller OD flange than the A-series item.





And finally, I decided against making my own manifold. If you do the maths and work out the total cost of making your own then Matt's prices look very reasonable to say the least so fresh off the Fusion Fabs production line this arrived on friday. Looking very nice indeed, top job *Clapping*







So now I've got the turbo position fixed I can make the downpipe and finalise the bulkhead boxing to clear the external wastegate. It seems I'll have to change the size of the bottom bulkhead as it was orignally sized to fit the GT17 and with the 20 clearance is a little tight *surprised*

Edited by adcyork on 1st Jun, 2015.


braad

User Avatar

140 Posts
Member #: 10115
Advanced Member

Sydney, Australia

mmmmm that is very tasty indeed! lovely work so far!


e5tus

User Avatar

140 Posts
Member #: 10128
Advanced Member

Dorset

Looking good, can't wait to see this complete.


Billus89

User Avatar

359 Posts
Member #: 8931
Senior Member

Herefordshire

This project is looking seriously good *Clapping*


theoneeyedlizard

User Avatar

7157 Posts
Member #: 1268
The Boom Boom speaker Police!

Essex

Very nice

In the 13's at last!.. Just


16vmini

37 Posts
Member #: 5037
Member

looking good , i see you got the lathe etc there , my dad and i have nearly finished our k1100 conversion my dad made all the parts :

bmw.16vmini.co.uk


vegar

User Avatar

520 Posts
Member #: 189
Post Whore

Norway

This look like a really good tought out build. I like it a lot :)

www.shag.no


jonny f

User Avatar

2027 Posts
Member #: 9894
Post Whore

Dorking

looks excellent!


D4VE

User Avatar

2909 Posts
Member #: 10749
Post Whore

lowestoft suffolk

Does look a nice thought out build...

Are the coilover turrets jon betts ones? And how do you carry on welding around the back? Or is it welded from the outside at this point???

On 24th Oct, 2015 jonny f said:
Nothing gets past Dave lol

NOTHING GETS PAST ME!! *tongue*

1/4 mile 14.7 @ 96mph 12psi boost
Showdown class A 2nd place 18.6 @ 69mph


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Thanks Dave. Yes they're a set of Jon's turrets and they're welded from the outside (wheel arch) as access becomes an issue round the back

On 11th Jun, 2015 D4VE said:
Does look a nice thought out build...

Are the coilover turrets jon betts ones? And how do you carry on welding around the back? Or is it welded from the outside at this point???


Joe C

User Avatar

12242 Posts
Member #: 565
Carlos Fandango

Burnham-on-Crouch, Essex

ah, found the thread,

just finally got around to checking my SC manifold flange against the head and it fits fine, so they have obviously corrected this at some point.

On 28th Aug, 2011 Kean said:
At the risk of being sigged...

Joe, do you have a photo of your tool?



http://www.turbominis.co.uk/forums/index.p...9064&lastpost=1

https://joe1977.imgbb.com/



adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York



On 19th Jul, 2015 Joe C said:
ah, found the thread,

just finally got around to checking my SC manifold flange against the head and it fits fine, so they have obviously corrected this at some point.



Interesting Joe. I didn't get round to firing mine back at them in time.

As some may have seen I was having serious trouble getting the driveshaft angles to work with the engine in a suitable position to clear the bonnet with about 8mm clearance. After much moving about and re drilling of the bolt holes a solution was found. An intermediate position about 5mm higher and 10mm further back was found which solved the driveshaft issue and resulted in a 5mm gap to bonnet, good enough!

Onwards and upwards!

I've been finalising the intercooler and plenum package which allowed me to get the plenum part finished. First of all I made a form tool to spin a set of trumpets up out of some 38mm Ali tube. Applying heat to the tube with a propane torch as the form tool was crashed into it made forming very easy indeed.



A little bit of refinement of the speeds and feeds and third time lucky



X4 after a bit of polishing



Next up was the plenum body which was designed for a 1.5L capacity on the basis of 1.15 x cylinder capacity for good transient throttle response, which will be key to offset any potential lag from running the GT20.





IACV flange turned up to suit a pug 306 rallye valve neatly packaged in the centre of the cylinder in the free space below. I need to sort out a spigot on the throttle body next to mate this to.



Modified Volvo S40 throttle body mocked up at the rough angle to meet the intercooler spigot



So the next step is to do a proper eng drawing for the intercooler and get it out for quotes. I'll be sending it to pace and concept custom. Does anyone have any other suggestions?


Edited by adcyork on 28th Jul, 2015.


matty

User Avatar

8297 Posts
Member #: 408
Turbo Love Palace Fool

Aylesbury

That's looking good!

Any more info on feeds and speeds and gauge of tube for spinning the trumpets? I've been wanting to have a go at this for a while now.

https://www.facebook.com/pages/Fusion-Fabri..._homepage_panel

www.fusionfabs.co.uk



1/4mile in 13.2sec @ 111 terminal on 15psi


adcyork

User Avatar

516 Posts
Member #: 6807
Post Whore

York

Cheers Matt

The tube is 16 gauge wall so about 1.6mm. It was cheap tube though so the wall thickness varied from 1.5mm to 1.8mm around the circumference which made things more difficult. Speed of 850rpm and it really is just a matter of feel from trial and error for the cross slide/feed rate because the distance is so small. Key is to keep it all lubricated with a high melting point grease so you don't get burning oil flying off at you as you heat the tube.

Home > Show Us Yours! > K1100 turbo track car build - Clutch Issues
Users viewing this thread: none. (+ 1 Guests) <- Prev   Next ->
To post messages you must be logged in!
Username: Password:
Page: