1968 Impala Turbo LY6/4L80e Swap - 798 RWHP @ 17 PSI
09-26-2015, 09:03 AM
#141
Here is the final pedal installation. The roll pin and safety wire worked great in addition to the pretty snug press fit the rod has into the pedal.
I had the final welding of the cold side finished up along with the beads rolled. Everything went together smoothly but I need a few more clamps.
I had the final welding of the cold side finished up along with the beads rolled. Everything went together smoothly but I need a few more clamps.
09-26-2015, 09:13 AM
#142
This is pretty much the final configuration. I still have the under car exhaust and running lines to the BOV and WG. I also have to make one cut and weld to fix the filler neck angle problem the curved hose did not fix.
I am making the tune appointment monday for the following week so I am forced to finish the exhaust by then.
I am making the tune appointment monday for the following week so I am forced to finish the exhaust by then.
BRAVO!! 
09-26-2015, 08:20 PM
#146
Blue Demon .030 309/309L with Stargon gas in a Hobart 140. I set it at about 22 CFM flowing for all welding. I have tried many combinations of heat and speed.
SS has never sounded right on this machine even on heavier gauges but I also have zero formal training on SS so I don't really know what it should sound like. It's weirdly inconsistent though. Sometime I get a nice bead going then it goes quiet and starts to burn through no matter what even when I re-start. The mild steel welds very nice and consistent. If I move very fast on the SS it seems to work but penetration also seems poor. You can see on one weld which was the last I just tacked it all the way around works well but is slow and can be porous.
SS has never sounded right on this machine even on heavier gauges but I also have zero formal training on SS so I don't really know what it should sound like. It's weirdly inconsistent though. Sometime I get a nice bead going then it goes quiet and starts to burn through no matter what even when I re-start. The mild steel welds very nice and consistent. If I move very fast on the SS it seems to work but penetration also seems poor. You can see on one weld which was the last I just tacked it all the way around works well but is slow and can be porous.
09-26-2015, 08:45 PM
#147
TECH Senior Member
iTrader: (7)
Bravo for putting out the good, the bad and the ugly. I always try to make my post as honest as possible. We aren't perfect and our mistakes are a great learning point for people that want to get something from our posts!
Andrew
Andrew
09-28-2015, 04:12 PM
#148
I finished plumbing the waste gate, boost controller, and BOV. I enjoy that kind of easy work. However I did not enjoy my wasted time trying to get the exhaust hooked up. I'm not making excuses here but I don't have the tools for custom exhaust work. I spent a bunch of time trying to make a 2 into 1 merge and gave up. I know I could to it but I need some stuff I just don't have room for nor do I want to spend the cash on it.
I also had some time to do a boost check. I purchased some plumbing parts and utilized my Harbor Freight leak down tester. This is a very new area for me and I almost crapped my pants with the cap blew off the turbo inlet at 6 PSI. The system seems pretty sealed up at 6-7 PSI but I already found an issue with the cheap hose clamps. I will have to get some new ones.
I was also able to confirm the second fuel pump is activating with pressure but I am not seeing the correct corresponding rise. I have an email in to see if there's a better way to test the boost reference.
At 15 PSI on the gauge and 50% leakage I have 6-7 PSI in the motor or at least I think that's how it works. Either way I am scared to push it to 15 PSI.
I also had some time to do a boost check. I purchased some plumbing parts and utilized my Harbor Freight leak down tester. This is a very new area for me and I almost crapped my pants with the cap blew off the turbo inlet at 6 PSI. The system seems pretty sealed up at 6-7 PSI but I already found an issue with the cheap hose clamps. I will have to get some new ones.
I was also able to confirm the second fuel pump is activating with pressure but I am not seeing the correct corresponding rise. I have an email in to see if there's a better way to test the boost reference.
At 15 PSI on the gauge and 50% leakage I have 6-7 PSI in the motor or at least I think that's how it works. Either way I am scared to push it to 15 PSI.
09-28-2015, 04:22 PM
#149
TECH Senior Member
iTrader: (7)
I would just test the system up to the throttle body. At any given point in time there are numerous intake and exhaust valves are open, so I am not sure what your leak test, as you have it set up, is really telling you, which is why you are showing 50% leak down.
Andrew
Andrew
09-28-2015, 04:34 PM
#150
I would just test the system up to the throttle body. At any given point in time there are numerous intake and exhaust valves are open, so I am not sure what your leak test, as you have it set up, is really telling you, which is why you are showing 50% leak down.
Andrew
Andrew
09-30-2015, 11:17 PM
#152
The final puzzle pieces are in place and ready to get finish welded. Between the stinky chop saw and rolling back and forth under the car I'm exhausted (pun intended). I fired it up for a second and it's going to be quiet, but I already knew that.
I swapped the cheapo cold side clamps for some Clampco's from McMaster. Huge difference in quality and USA made. I will do a final boost leak check then throw the hood on. I hope to get a few miles on it over the weekend.
I swapped the cheapo cold side clamps for some Clampco's from McMaster. Huge difference in quality and USA made. I will do a final boost leak check then throw the hood on. I hope to get a few miles on it over the weekend.
10-01-2015, 08:44 PM
#153
The exhaust is welded and installed. I have it as tight as I can get 4" under the crossmember. I did some measurements and I should still have about 5" of ground clearance at the lowest point. I also warmed it up again to leak check it for about 30 minutes. The turbo drain flange needed to be tightened and the stupid cheap brand new radiator petcock tab thingie stripped. I just had one do the same thing on my air compressor. It's either me or all the petcocks available these days are made of tin foil.
Tomorrow will be the maiden voyage to the new gas station on the corner to fill up with some EEEEEEEEEEEEEEEEEEEE.
Tomorrow will be the maiden voyage to the new gas station on the corner to fill up with some EEEEEEEEEEEEEEEEEEEE.
10-01-2015, 09:21 PM
#156
TECH Senior Member
iTrader: (7)
I'd love to take a drive in the Cougar and come check out this build first hand.
Andrew
10-02-2015, 05:40 AM
#157
I'd like to check out this controversial Cougar myself. I hope to get some runs in at Great Lakes Dragway before the snow flies, that might be a easy spot to meet up. The car will also be at Late Model Throttle in Waukesha for dyno tuning hopefully next week. We will see how it does with a few miles on it. I am super nervous about thrashing a basically brand new unproven drivetrain on the dyno.
10-02-2015, 07:36 PM
#159
Assuming I am reading this correctly and you have no mufflers, it is impressive how quiet it is by splitting it into two and running it out the back. Sounds fantastic. Will be fun to see what it sounds like on the road.
