dropnosky's 115 chassis project

dropnosky's 115 chassis project - Printable Version

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RE: dropnosky's 115 chassis project - Simpler=Better - 07-07-2012

Nooooooooooooooooooo! Want a 300D N/A pipe? I'll let it go cheap if you use it Smile

The outlet points kinda back and down though...

RE: dropnosky's 115 chassis project - JB3 - 07-10-2012

(07-07-2012, 05:38 PM)Simpler=Better Nooooooooooooooooooo! Want a 300D N/A pipe? I'll let it go cheap if you use it The outlet points kinda back and down though...

The S pipe is totally salvageable, just has to be cut apart, and lengthened. Ironically, part of the problem is the shock tower tab I just welded to the car. Big Grin

In a better mood now that ive got the trans in and other measurements are good.

Engine being installed-

[Image: 001-1.jpg]

used clutch installed, about 70% life on it.

[Image: 002-4.jpg]

gearbox installed. Slight issue at the mount. The W201 gearbox is very close to the W115 cross member, will have to trim the cross member slightly. Theres no way it won't hit without clearance

[Image: 006-3.jpg]

Custom driveshaft and used axles-

[Image: 005-3.jpg]

Driveshaft installed, fits nicely-

[Image: 007-3.jpg]

Lots of stuff left to to before I can see if it runs-

install axles
install shift linkage bars
Remake and install turbo S pipe
Install turbo
Install exhaust
install oil filter arrangement
install clutch hydraulics
resolve cooling system
hook up heater core ect ( I damaged the stock pipe on the firewall unfortunately)
Install starter
Install battery in trunk, run cables up
connect throttle arrangement and pedal (broke off floor due to rust)
work out glow plugs
work out power steering

More im sure, just a short list of high points

RE: dropnosky's 115 chassis project - Simpler=Better - 07-10-2012

(07-10-2012, 07:58 AM)JB3 Lots of stuff left to to before I can see if it runs-

Remake and install turbo S pipe
Install turbo
install oil filter arrangement
resolve cooling system
Install starter
work out glow plugs

There I fixed it Big Grin

RE: dropnosky's 115 chassis project - JB3 - 07-11-2012

(07-10-2012, 12:34 PM)Simpler=Better There I fixed it

thanks, this is a good idea, making 2 reminder lists for myself (gonna add as I go along)-

Little things not to forget

1. Fill diff (complete)
2. torque rear wheels
3. fill transmission
4. correct bolts for carrier bearing (complete)
5. engine to chassis ground, passenger side near starter, move driver side?
6.nip trans mount interference with gearbox
7. nip lower oil pan interference with front part of subframe (accident damage)

big things left to do

1. oil filter and oil thermostat
2. Turbo S-pipe remade correct
3. Cooling system
4. turbo with correct oiling
5. Power steering hookup
6. oil cooler install
7. vac pump, new one? move over from 616 engine? connection to brake booster
8. shifter linkage bars measured out
9. clutch master and slave installed, and bled.
10. glow plugs
11. throttle.
12. engine shock
13. custom brace
14. battery and starter, with cable connection to trunk

CUSTOM HOSES TO MAKE

1. oil filter head to remote plate on engine. AER 202702-12-10S fittings 4ct, SAE no 10 37 degree flare
2. Power steering pressure side, stock fittings, 115-116 ends

RE: dropnosky's 115 chassis project - JB3 - 07-11-2012

axles in, diff looks good-

[Image: 013.jpg]

starter in-

[Image: 005-4.jpg]

and I think the problem here may be clear. oops. Back to the drawing board.

[Image: 006-4.jpg]

RE: dropnosky's 115 chassis project - DeliveryValve - 07-11-2012

Nice progress despite the issues.

(07-11-2012, 03:18 PM)JB3 axles in, diff looks good-

What's that spacer on the spring? Never seen one like that.

(07-11-2012, 03:18 PM)JB3 ....

and I think the problem here may be clear. oops. Back to the drawing board.

I don't know man, but I think the Cali Manifold and bypass pipe is looking way better at this point.

.

RE: dropnosky's 115 chassis project - JB3 - 07-11-2012

(07-11-2012, 03:26 PM)DeliveryValve Nice progress despite the issues.

What's that spacer on the spring? Never seen one like that.

I don't know man, but I think the Cali Manifold and bypass pipe is looking way better at this point.

.

the spacer is on both sides, its some kind of soft, pliable rubber. I have no idea, but i think its oem to this 115. Maybe some kind of noise damper?

no no! Ill make it work! Big Grin

(plus I cut all that stuff up anyway to make this)

All I need to do is cut this apart, extend it, and pitch it back to open up the space. Also, secondly, the over the long runner manifold brace is too high, so ill be remaking that to run through the manifold instead.

RE: dropnosky's 115 chassis project - Simpler=Better - 07-12-2012

Here we go:

Those rubber spacers are cheapo autozoo "coil stiffeners" or "lift kit" depending on how you install them. Some people worry about how they are set up on your car, something about stressing the wrong parts of the spring. I ran them as a lift kit on my w123 under the coils.

RE: dropnosky's 115 chassis project - willbhere4u - 07-12-2012

You need that BSA turbo Exhaust manifold

bottom of this list http://www.superturbodiesel.com/std/thread-1694.html

RE: dropnosky's 115 chassis project - JB3 - 07-14-2012

(07-12-2012, 07:52 AM)Simpler=Better Here we go:

Those rubber spacers are cheapo autozoo "coil stiffeners" or "lift kit" depending on how you install them. Some people worry about how they are set up on your car, something about stressing the wrong parts of the spring. I ran them as a lift kit on my w123 under the coils.

Suspension is next on this car long term, so ill resolve that later I think. I might pull em out though, car does drag ass a little. Need to run a carfax and check its history, lots of college stickers from early 2000s

(07-12-2012, 11:58 AM)willbhere4u You need that BSA turbo Exhaust manifold

bottom of this list http://www.superturbodiesel.com/std/thread-1694.html

that does look like it would work perfectly! I should be able to remake this though, hopefully in the next couple days.

Updates, I got a nice moroso filter head in the mail, pics later on. Im thinking oil filter might go where fuel filter currently is, and fuel filtration relocated elsewhere.

RE: dropnosky's 115 chassis project - JB3 - 07-18-2012

Oil thermostat arrived, so here are some pics, and where Im going to put this oil filter.

This is the Moroso head with 3 outlets, two small, which will work perfectly with the stock needs for turbo oil line, and mechanical gauge-

[Image: remotefilterhead.jpg]

Here is the Moroso head with a Bosch 3500 filter, made for 60s and 70s large V8 applications and some euro stuff. One of the larger spin on filters I could find by just walking around and threading filters on the head with in stock items in either MANN or Bosch brands. Next to it is the stand alone oil thermostat unit, rated at 180 degrees

[Image: 011.jpg]

Here is an extremely nice oil relocation plate made for me by 300D50. Upon consideration, I won't be using this exact unit however, ill be making a 1/2 plate that is much simpler, and welding 37 degree flare fittings directly to it, to match the filter head fittings.

[Image: relocationplate.jpg]

back side-

[Image: relocationplate2.jpg]

the oil filter will be going where the fuel filter currently is, and fuel filtration will now be moved to under the vehicle, near the fuel tank. Space for this oil filter has been quite difficult to find. would have been too low under the car anywhere, and would have fit in front of the LF tire, but not without disadvantages. This I think will be best

Stock setup-

[Image: stockfuel.jpg]

I removed the stock filter head, replaced the lift pump with an updated version, and direct plumbed from the lift pump to the injection pump, making room for the filter-

[Image: 009.jpg]

here is where it will sort of sit-

[Image: 013-1.jpg]

The oil thermostat will be in the input line to this filter head, like the stock arrangement. That may be mounted to the frame under the power steering pump. I need to get everything hard mounted, and its custom hose time.

I need 5 custom hoses for this oil filtration arrangement.
1 custom hose for the pressure side on the power steering pump, and 1 custom hose from the filter head to the turbo input.

7 in total.

RE: dropnosky's 115 chassis project - JB3 - 07-19-2012

oil filter installed-

bracket and the thermostat next to it, now to make some custom hoses and a relocation plate for the motor

bracket-

[Image: 0042-2.jpg]

couple angles-

[Image: 005-5.jpg]

RE: dropnosky's 115 chassis project - willbhere4u - 07-19-2012

what are you doing for a fuel filter?

RE: dropnosky's 115 chassis project - JB3 - 07-20-2012

(07-19-2012, 05:36 PM)willbhere4u what are you doing for a fuel filter?

a canister filter underneath somewhere near the fuel tank. I have a couple nice examples left over from a job I might try.

RE: dropnosky's 115 chassis project - lgreeley83 - 09-27-2013

This build is awesome! I missed most of it while in Egypt I guess. I thought A swap was as easy as just moving the oil filter housing. Guess I won't be doing this anytime soon. Lol.

Did you get that turbo right yet?

RE: dropnosky's 115 chassis project - JB3 - 09-27-2013

(09-27-2013, 08:00 AM)lgreeley83 This build is awesome! I missed most of it while in Egypt I guess. I thought A swap was as easy as just moving the oil filter housing. Guess I won't be doing this anytime soon. Lol.

Did you get that turbo right yet?

Thanks!
Been stalled for a while as life got in the way, latest delay is lent out my co2 tank for my welder to next door body guy. However, I'm getting around to fitting the manual steering box and seeing if it works. If I can get that to fit on this chassis, will make a huge difference on oil and fuel filtration room in the engine bay.

Havet got a new turbo s pipe rigged up yet , soon though! Want to get this sob running

RE: dropnosky's 115 chassis project - Simpler=Better - 09-27-2013

Bam, I fixed it in like 2 hours welding:

RE: dropnosky's 115 chassis project - EmJay - 09-30-2013

for the fuel filter, NAPA sells a universal setup for like $25 and filters for $10. That is what I am using for my diesel build.

you can see it here:

[Image: IMG_20130903_192152_769_zps9fc160cb.jpg]

RE: dropnosky's 115 chassis project - JB3 - 10-06-2013

(09-30-2013, 11:38 AM)EmJay for the fuel filter, NAPA sells a universal setup for like $25 and filters for $10. That is what I am using for my diesel build.

you can see it here:

Didn't know that napa sold those heads! Thanks for the info.

Honestly, I'm going to try and fit a toploader turbine filter/water seperator instead of a canister. It may end up in the trunk

RE: dropnosky's 115 chassis project - sassparilla_kid - 10-07-2013

I'm sitting on the edge of my seat waiting for you get that turbo mounted, so I won't have nearly as much to engineer when I turbo my 240 Cool

RE: dropnosky's 115 chassis project - JB3 - 11-27-2013

so making some slight progress getting the turbo mounted, some pics of my new S pipe for this.

Going to end up being made up of a dozen little pieces because of the compound curve and twist, but ive been inspired by looking at some header production pics on some of the threads on here and started a lot wiser this time. Lots of welding left to make it really solid

The turbo is going to live in this region-

new S pipe, structural bits to support the turbo ill do later on after this is done

also BBS rims balanced and mounted. Look great on the old 115 chassis, matches the age perfectly in my opinion

RE: dropnosky's 115 chassis project - Greazzer - 11-27-2013

Very, very nice work !

RE: dropnosky's 115 chassis project - JB3 - 11-30-2013

(11-27-2013, 07:51 PM)Greazzer Very, very nice work !

thanks! getting there slowly

so ive got most of the turbo mount setup, it got a little over welded here and there. Of course, a header would be better, but later on ill try something like that. This arrangement is to test out this drivetrain, one day it will have the intercooler, header, ect

To preface, I will be doing a ton of grinding to these parts to make em look better before painting them, but here are some pics-

The turbo mount ended up looking like this, a two piece thingamabob-

First you install the lower S-pipe and support, putting it up through the long runner intake manifold (instead of over as my previous plans were)

Then you install this part on the valve cover and bolt them together, the bolt heads are an integral part of the lower piece. I set it up for easy access from above as the motivation, if you drop the nuts and washer, they fall in a little cup instead of into the lower engine bay area-

here is the turbo resting in the approximate position. When I reclock the pipe, a 45 degree hose should have it meet the long runner intake

Also, it looks like its sitting on the fender, but there is a ton of room under there-

Here is how it looks from this angle. Im still undecided if I should do another extra bracket using the studs on the exhaust manifold like stock. I may do that later, probably worth it since all the stock turbos had that second bracket, would be worth triangulating

RE: dropnosky's 115 chassis project - mike-81-240d - 12-01-2013

Yessss glad to see the wheels on the car.

RE: dropnosky's 115 chassis project - JB3 - 12-01-2013

(12-01-2013, 02:30 AM)mike-81-240d Yessss glad to see the wheels on the car.

It only took 2 years for me to get around to it!

Big Grin

RE: dropnosky's 115 chassis project - sassparilla_kid - 12-01-2013

I don't think I have that stock extra bracket on my manifold anymore, something tells me I got pissed off at it and threw it into the garage or something

RE: dropnosky's 115 chassis project - JB3 - 12-01-2013

Bunch more pics-

S-pipe wrapped and painted-

how it looks installed with the long runner intake off-

Im still deciding how I want to do this second support like stock if I can. Obviously its gonna require a bracket, but im not sure how useful the support will be without a 3rd bolt of its own covering that kind of distance-

Meanwhile I had to remove the coupling to make room for the downpipe from this angle. There is an A/C line clearance issue to be worried about. I cannot absolutely say im not going to want A/C at one point, so id hate to remove this line-
better with the coupling removed though-

lots of room going down from this angle-

Im doing a 3 inch downpipe, direct from the turbo, clearance looks ok-

Another idea is to do a flex joint below a bracket and use the curve of the downpipe as a form of structural support in itself, or even off the bell housing-

similar to this type of bracket as an example-

RE: dropnosky's 115 chassis project - JB3 - 12-02-2013

ok, throwing out all that earlier plan and remaking a 90 degree pipe instead of an S, and/or making a header.

Ive been doing several weird things-

1- Ive been making a compound curve S pipe because Im not familiar with turbos and didn't realize how easy it would be to reclock this thing.
2- A small diameter pipe S is incredibly restrictive right before a 3 inch exhaust. That arrangment makes no sense.

RE: dropnosky's 115 chassis project - Simpler=Better - 12-02-2013

(12-02-2013, 01:06 PM)JB3 ok, throwing out all that earlier plan and remaking a 90 degree pipe instead of an S, and/or making a header.

Ive been doing several weird things-

1- Ive been making a compound curve S pipe because Im not familiar with turbos and didn't realize how easy it would be to reclock this thing.
2- A small diameter pipe S is incredibly restrictive right before a 3 inch exhaust. That arrangment makes no sense.

The feed pipe is seeing what, 20psi? The exhaust *should* be seeing "0" psi. The turbo outlet is usually larger piping than the inlet.

As for a header, oh it's going to be absolutely better than a stocker+S pipe. But you're going to spend a lot of time hunched over in there unless you have a spare head.

For the 5-1 transition there is a website that prints out paper templates for wrapping around a pipe, so that you can cut your weird merge angles for welding. I'll be darned if I can remember what it was called.

RE: dropnosky's 115 chassis project - JB3 - 12-02-2013

(12-02-2013, 01:46 PM)Simpler=Better
(12-02-2013, 01:06 PM)JB3 ok, throwing out all that earlier plan and remaking a 90 degree pipe instead of an S, and/or making a header.

Ive been doing several weird things-

1- Ive been making a compound curve S pipe because Im not familiar with turbos and didn't realize how easy it would be to reclock this thing.
2- A small diameter pipe S is incredibly restrictive right before a 3 inch exhaust. That arrangment makes no sense.

The feed pipe is seeing what, 20psi? The exhaust *should* be seeing "0" psi. The turbo outlet is usually larger piping than the inlet.

As for a header, oh it's going to be absolutely better than a stocker+S pipe. But you're going to spend a lot of time hunched over in there unless you have a spare head.

For the 5-1 transition there is a website that prints out paper templates for wrapping around a pipe, so that you can cut your weird merge angles for welding. I'll be darned if I can remember what it was called.

my plan for the 5-1 merge is to cut up toilet paper tubes and work it out. Big Grin

My issue with the feed pipe is that the S is restrictive needlessly over a much simpler and better 90 degree bend, that wouldn't have the rough surface inside, and would be essentially two welds to make it work, as well as eliminating the compound curve that ive built into this S. I could adjust the direction of the flange to point anywhere by just rotating it on end of a 90 degree section of pipe

RE: dropnosky's 115 chassis project - sassparilla_kid - 03-05-2015

Any update on this? I just read through it again and the whole time I was looking at your "S" pipe I was wondering why not just have a 90, then I got to the end and saw you came to the same conclusion! haha

RE: dropnosky's 115 chassis project - TurboTim - 03-05-2015

Yeah I would love updates too. I just started this swap blind and found out about the oil filter when I installed it. I am thinking about trying to convert to a hydro boost setup And use the cali manifold so I can keep the stock throttle and trans linkages.

RE: dropnosky's 115 chassis project - sassparilla_kid - 03-05-2015

I think with a 90* adapter it's gonna need to have sort of long legs to get it out far enough from the manifolds and up off the inner fender

RE: dropnosky's 115 chassis project - JB3 - 03-10-2015

Update is the car and all other projects are on hold until i create some place to work on them, in the works for this spring. Once i have some concrete in place i can move forward finally. Would like to see this car actually run again