1600 single port turbo blow through w/pics, baja header

[san diego baja]

hey guys! semi new to STF but i have done alot of reading especially in the off road and forced induction . so i have begun my budget 1600 single port build for my baja bug

first lets start. this is my baja bug , it currently have a 1600 DP with super trapp exhaust, and kardon 40/44 dual carbs , empi bolt on valve covers basically stock other then that, rancho pro perfromance T1 transmission




in an effort to not explode my motor that i have now ( which hasnt leaked a drop of oil since i bought it ) i picked up a spare 1600 SP on craigslist for 300 turn key



it came with a solex 30/31 carb and is completey stock HOWEVER it is a 1300 type f case which is somewhat concerning, or is it? im not too familiar with the cases on these engines but im assuming its not as strong as say a 1600 case. i will be installing a rev limited at 5500 RM, does that sound safe to you guys? I will be modding the carb just like everyone does with the 34 pict3 . actually the 30/31 is only 1mm smaller then the 3 i believe (correct me if im wrong) ether way, im sure it will be usable, if not i will upgrade thats no problem . so i went out and bought a baja header that i will be using for my turbo for 100 $ from the local shop , i know i should have waited and bought one for cheap, but none came on craigslist for months so i just caved here it is installed




I also bought a cheep turbo from ebay ( im sure i will get plenty of S#%^ for this haha) it is a t3/t04e turbo i know i know, its big for this application , However i am completely satisfied with it thus far, it seems to be very well constructed and came pre balanced , , i also bought a restrictor for the oil feed from ebay.




also, these are the cheap o rings i bought from craigen i think , will they work for this ? apparently they are rated for gas so they should be ok rights?


I will be keeping this updated will its finished, any suggestions or advice would be GREATly appreciated


here are also a few random pictures of my baja




before

after

[san diego baja]

sorry i thought i posted the o rings picture, here it is

[hugging corners]

great!! those o rings look identical to HF viton o rings, but are you sure they are viton because there is 1 more type that is solvent resistant but not sure if you can use it
viton is slightly blueish in color
good luck
ps: how often do you torture that rock behind your house?:)

[Clonebug]

The sizes you need are 008 and 011.

Clonebug

[miniman82]

also, these are the cheap o rings i bought from craigen i think , will they work for this?

Sorry I've read this post 3 times, what is 'this'?

[san diego baja]

i apologize, "this" would be sealing the caruretor shafts for blow through and the fuel pump for boost referencing


, Also in the forums i have seen people do boost referencing on their fuel pumps they dis assemble them to do it, this is my fuel pump as it stands and it doesnt come apart, is it still usable ? also if you notice there is a small hole for it to breath in normal conditions, should i just drill this hole out to attach a pressure line ?





the only thing stamped on the other side is " made in brazil"

[Clonebug]

I just drilled the vent hole out to larger size.

I first drilled it to 3/16ths and had the JB weld break loose from bumping it around.

I then took the pump off again and drilled the hole out to 1/4 inch. I drilled 1/4 because that size matched my boost port on the turbo.

You have to be very careful due to the fact that the diaphragm spring is right there.

I drilled just about 3/4ths of the way through the pot metal to leave a slight ridge for the tubing to rest against without sliding all the way in.
Put the JB weld on the tubing and when you insert it into the hole give it a nice twist to coat everything with the stuff. I made sure there was plenty on the outside to support the tubing. Put the pump in a vice gently to keep the hole and tube vertical while it dries
You still have to be a little gentle handling it to make sure you don't break it off. Also make sure you don't make the tubing too long since it is on the back side and difficult to see. I think my piece was about an inch long. You have to leave room for the hose to bend around the corner and up to the turbo wastegate reference port.
Do not let the pump reference vacuum....only boost.
On my build I took pics of the old style fuel pump that I modified but that pump was DOA and I ended up using a newer pressed together style like you have.
It has been working fine for 3000 miles so far.
Others have drilled and tapped the casing to accept a brass fitting.

Clonebug

[hugging corners]

i was gonna write earlyer about those ring being ok for pump shaft
"this" you actually mean carb shaft?- good observation
firstly- kadrons usually dont need sealing where 34pict would need
These Oring will be no good for the carb i believe. Remember that o-ring usually sits in places like injectors, does not move

but here its on the shaft it will be in constant motion w/ fuel and vacuum
Harbo.r Freid sell the twice larger pack of vitons for 20 bucks. I got it it will last me tilll retirement when i'll start building airplanes... .. . !!:) ,so i recommend

and i think you can run your carbs stock.

In actuallity i am building very similar set up to yours with 34pict's turbo dual carb
we mignt compare results in some time, and prolly tuning and jets will be similar.
good luck

[san diego baja]

recently i bought a " turbo oil supply kit" from ebay, and im very impressed with it, Origionally i had bought a seperate oil restrictor and seperate "T" fitting for the plumbing, for half the price this kit comes with everything you need, including the restrictor, t fittings, braided steel oil line, t3 inlet and the mounting blots for it , it was 21$ shipped . this is what it looks like installed




two other things i bought, a 5 bolt exahust flange for10$ shipped (IMO worth the money of making a difficult flange) and an RPM gauge , its slowly coming together

[san diego baja]

http://cgi.ebay.com/ebaymotors/UNIVERSA ... 27ba48b537

[san diego baja]

drilled and JB welded my boost tap for the fuel pump...... i may have gotten a little carried away with the JB weld but i figured this would be a weak point






I also got a little crazy with the sawz all and cut my header a little uneven (damn dull blade) ,so i ill be using the angl grinder to smooth things out this weekend, this is why i decided to go with this set up , look at the fit!

[Clonebug]

drilled and JB welded my boost tap for the fuel pump...... i may have gotten a little carried away with the JB weld but i figured this would be a weak point






I also got a little crazy with the sawz all and cut my header a little uneven (damn dull blade) ,so i ill be using the angl grinder to smooth things out this weekend, this is why i decided to go with this set up , look at the fit!

Your pump looks fine that way. I used plenty of JB-Weld too to give it support.

Clonebug

[san diego baja]

just a thought! has anyone tried a t3/t4 turbo on a 1600 motor? what kind of boost did you get? obviously im not expecting and boost till later in the RPMS, im also going to go to a .48 a/r when i eventually find a housing ..... just curious . MANY updates comming in the next two weeks i should have my motor ready for testing

[san diego baja]

had a couple hours to work on the motor last night , got the t3 flange welde on as well and an intake , here is wht it looks like





, i welded the intake from the part of the exhaust i cut off, here it is with the nipple for boost referencing tapped and sealed in





i ran into a problem with my cheap ebay oil feed kit, and i will admit this was my fault , i over tightened the fitting anf broke it , a new kit is on the way, 20$ in the trash




here is what the exhaust will look like, i bought it for 6$ at craigen




I also finished preping my carburetor for turbo use, including viton shaft seals and soldered the E tubes, i bought a 130 main , but im sure i will need to order plenty more based on what im reading, i do have a few questions about these tubes that were previously capped off by the PO , should i leave them capped? are they for vacum lines or what??

[san diego baja]

well im just about finished, just need to weld a cap on the intake , I finished the exhause as well as most of the oil drain, i just need to order more jets and get a few gaskets for the carb from the shop, it will be a couple weeks till i can post some video of it running and test results