Om605 compound turbo build, my Corolla Ke70 tracktoy

Om605 compound turbo build, my Corolla Ke70 tracktoy - Printable Version

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RE: Norwegian OM605 build -> 1980 Ke70 Corolla - StrikerofDeath - 10-13-2014

any video?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 11-07-2014

Sorry guys, long time since I have updated here... :/

But last update ended with compound working great! and about one week later it was time for a new day at the track. Startet the day before to look over the car and doing minor adjustments when I spotted oil swetting for the small turbo.. but to access this, the big had to come out

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But got it fixed, and ready to og to the track!

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Stoped to fill up on the way, and of corse truckfuel straigt in the trunk! Big Grin

(called taxfree in norway, because its a bit less tax on it, an illegal to use on cars...)

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And at the track

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This was a trackday made by Toyota Norway, and its free driving for any Toyota owners.. And having a Ke70 here gives quite alot looks, but every time I fired it up EVERYONE looked at this :p Dont think anyone was expecting a diesel yota :p
Back to the car, it worked like a bullit, packed a good punch from 2000rpm and full boost (over 3bar) from 2600rpm to 6500rpm. It had a bit much backpressure, so I ordered a bigger LP turbo between the driving Smile

Sinse it worked this good, we startet to give it more boost, but then it didnt make more than 2,5bar. drove in ang checked all tubing to/from intercooler after leaks, but dident see anything. adjusted up more and tried again, but no help. continued some laps and then it ended here.....

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Smashed 3.gear in the longest turn, straght of, and had to be towed back to pit. Back there we found a torn of pressurehose that caused the leak.
Also I had borowed an other steeringwheel, and that made the car much much better to drive!

Some more pics from the driving

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And my daily, now towing the trailer Smile

I have also got some parts in that I wil get in this Winter, first up, a new boost gauge. Should be just enought Wink

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and the new turbo! Big Grin

Holset HX40W, 60mm compressor, 64mm turbin, 18cm exhaust

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16kg of turbo art Big Grin

And I have got a new gearbox, 6speed BMW diesel rewelded to fit the engine. This time it should hold!

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Old Mercedes Box VS BMW box

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I really hope that the Box fits the tunel.. shit is long....! :p
new clutchplates are on the way Smile

And a short Movie from first startup With new turbo

http://vid172.photobucket.com/albums/w20/stamsaas/Ke70/Snapchat-20141011070935_zps6hbr5inf.mp4

this is where we are today, after the brakedown i got tired of the shit, but time to start working on it again now! Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - raysorenson - 11-07-2014

You should have known better than to even bother using 3rd ;p

What powertrain is in your tow vehicle?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 11-07-2014

Yeah, probably I should, but I have to because of the gear ratio... :/ It hold quite alot tough. It couldnt hold the grip out the Third gear, it spun loose in every turn, and out in straights Big Grin

My daily? Its a 1,9TDI 4Motion remapped and strightpiped Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Gasoil - 11-10-2014

The rear of that Corolla is very close to a BMW E30.

Passat is remapped, straighpiped, slammed and wheeled!!!!!!!! Very very nice.......

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 11-20-2014

Yeah, the Ke70 is very much lika a baby E30 Big Grin

Thanks, short Clip of ridehight and sound in the Passat here;

https://www.youtube.com/watch?v=2Un3kMTqsaA

Now its 2-3cm higher and ready to drift some snow Big Grin

I have now got the New clutch discs for the 3plated clutch

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and I have made a litle New piece of tube from the big turbo to the small turbo

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its quite tight Space Down on the side there.... soon time to try to do the gearbox swap Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - StrikerofDeath - 11-23-2014

like it! no movie?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - hents99 - 11-24-2014

If you need flywheel for 184mm multi disc clutch then I have them.

[Image: 48279-DSC_2976.JPG]

As well as hydraulic clutch release bearing.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 01-10-2015

WOW, That is an amazing looking flywheel! Big Grin

I allready have a custom flywheel, but next time I want that one! Big Grin

Today I have made up a downpipe, the Holset v-band is an hard size to match, so I welded an New v-band on it, and angeled it a bit Smile

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Then i made up a New pressurepipe from cooler to intake. The new hoses are 4layer with armor.

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So then it was pressure Sealed again! Big Grin

Next was to move the car over to the lift, and start the gearboxswap, so I tok outside og let it get som temperature. just had to......... Big Grin

Turbos are not adjusted corecktly, but it Works Wink

kinda slippery also...

Next, in the lift, get the Box out!

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BMW Box is 25cm longer, and weights about 2-3 times as much as the merc box :p

Out With the old Tiltons, and in With the new ones

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And here we are, contionue to get the Box in tomorrow Smile

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RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 01-11-2015

Continued today, and started with measuring alot around the clutch and clutchhousing. Its very very tight in there! But got it together Big Grin

Did not take many pics today, but got the Box liftet and got all the screws in Smile

After that I made a frame to gearboxmount, and it became like this

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And the Corolla is official a 6speed! Big Grin

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The gearlinkage must be shortened with about 10cm (it is already shortened to fit Mercedes), så that is not in yet Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - rolfts - 01-12-2015

love it!

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - F.R.A.S - 01-12-2015

Awesome intake manifold Smile

You have the 53dz gearbox right? Looks like that. It's a big mother f***er Big Grin

No more gearboxes breaking anyway... Damn cool car.

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Ksteen2 - 01-14-2015

what kind of tranny??
I tought the bmw was 10 spline?
only 5 speed maybe?

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 01-15-2015

Thanks guys Big Grin

the box is å GS6-37dz. Only the 530D box, both 5and 6 speed have the 10 spline shaft. I cant have å 5speed due to the very short gear ratio Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 01-18-2015

Delivered gearlinkage and driveshaft today, and it might getting started on tomorrow Wink

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - seanyt - 01-26-2015

Loving this project. Lots of custom work.
I'm working on q compound setup also. What HP turbo are you using and what size wastegate have you got.

Mine is much tamer than your setup though.

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - maxypriest - 01-26-2015

Look at the size of that bmw flex disc!

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 01-27-2015

Thanks! Have dine some more, and driveshaft is back, but no pics yet.
I have Hx30 and Hx40 now Smile

and 50mm wastegate Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Ksteen2 - 01-28-2015

where can I find gear ratio?
I can't find the ratio on my merc 6 speed box Sad

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Max - 01-28-2015

Maybe this Link will help you

http://www.rodionenkin.de/de/pages/mb-superturbodiesel/mb-716.6-6-gang-schaltgetriebe-technische-daten.php

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 02-10-2015

Well guys, was going to make som shit done last saturday, and went to the garage. Startet with swapping the 3bar gauge with the 4bar gauge. Then it was up in the lift, to finish up the gearshifter, and try out the driveshaft. Then i met the brick wall. Shaft is not working good, and have never really been good and is probably the reason the drive in the rear diff got f**kt up the first season. This made me loose all my motivation, and took the car down again. Day after I put the car out to sale on some facebook pages to check the interrest....
Was in the garage again yesterday, to sell som other stuff, and was tempted to try start it. As usual, it never leaves me down, and fired at first krank. It is a bit Cold in the workshop, and it makes it og rough when Cold, and smokes like a bitch, but after a litle while I could start reving gentle, and a easy rev up to 4000rpm showed 0,4bar on the new gauge. This makes it all a litle fun again! Smile

Car is not sold yet, and today I got a fair price for a custom buildt one-piece driveshaft with some large cojonas from a driveshaft shop. Now I just need to deside, order driveshaft, or sell the car... But it would be a shame not to get it to the dyno! Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - mantahead - 02-10-2015

order drive shaft and have some fun Cool

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Ksteen2 - 02-10-2015

Not sell Alex, Fack, that car is just å beast!
Lots of torque, Low weight, car looks
"Hür kul som helst"
The most awesome thing money can buy! ?

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Tito - 02-13-2015

Don't buy the driveshaft and sell it to me! Big Grin

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 02-14-2015

Sorry Tito, but not for sale anymore, driveshaft is ordered Wink

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 02-28-2015

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Mr_Robs - 02-28-2015

This build is absolutely EPIC.

KE70 is such a cool chassis and now you have the best drivetrain ever Big Grin

So glad you didnt sell it, cant wait to see a dyno run!!!

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 04-15-2015

Time to update this now!

Got the new axle a while ago

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Also got another litle thing;

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Rocket Bunny rear spoiler <3

After that I got the pedals in again. Are going back to the Mercedes pedalbox again, I did not like how the "racing" pedalbox was. Got all the brakelines fished Smile

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And got some color on the bunny Smile

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To fit the driveshaft, I needed a adapterplate between the gearbox and the shaft. Got all the measurements, and ordered the Production.

Meanwhile I made a custum gearshifter rod, and got the shiftermechanism to fit. This was a real pain in the ***. Very litle Space.. But ofcourse, the Merc/diesel/truck Wood ball is in! Smile

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all 6 gears and reverse is found!

Finaly the adapter was finished!

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Axle test fited

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This is so much bigger, and needs so much more room to fit :p

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And some cutting later, it is complete! Big Grin

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Got the lines finish to the slavesylinder to the gearbox, and with a Tilton valve in Smile

Just need to make a bracket to the clutchfluid container, and it is ready to bleed Smile

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Yesterday I had a friend With me, and I put hiim in the car to pump the pedal. Started on the brakes, but after only a few push the link from the pedal to the brakepowerboxthing broke of in a welding. so it must out again to see what happend, and to reweld it better. So the bleeding stopped there. Getting closer to a testdrive now Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Turbo - 04-16-2015

stamsaas how does boost pressure for both turbo looks like ovewr increasing RPM and the backpressures for both turbos, have read this treat with great pleasure many time but have I miss it?
Can you please PM me price for flywheel?

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 04-22-2015

I have not adjustet any pressure on the turbos yet, so I dont know now how they will end up. Last setup was about 1bar on the He351w, and the rest on the Hx30, but the he was to small and backpressure was way of Smile

will try to det it up as fast as it is driveable, and make the finetuning in the dyno Smile

I only have my flywheel, and was planing og keeping that :p

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-04-2015

Friday was garage day, and I got the the clutch reservoar bracket made, and aired out the clutch/slave Smile

fired up, and clutch worked but did not disconected enough. So had to make the slave arm 10mm longer Smile

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And that did the trick! Put the wheels back on, and got it out of the garage, testdrive time! Big Grin

And some photos Smile

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Must have a video with some smoke :p

Marking its teritory!

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Are dealing with the dynoguy atm, finding a time soon as posible Big Grin

just have to make the exhaust ready, and test it a little more. Maybe Dyno next week? Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-06-2015

Next week it will be dynoed Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Turbo - 05-06-2015

will be very interesting to see Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-10-2015

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - svenr - 05-10-2015

Nice throttle response Smile

ready to rock and roll.

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-14-2015

Yesterday this happened!

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RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - DiseaselWeasel - 05-14-2015

You tease!! Big Grin

We ant results! Big Grin

Have followed this build silently - I think it's my favourite on here! And god, I love RWD Toyotas!!

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-14-2015

Will come back later with more details, but maxed at 398,5whp and 550wnm Big Grin

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - DiseaselWeasel - 05-14-2015

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RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Booster - 05-14-2015

So Much win in this Build!!!

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-30-2015

Thanks guys! Big Grin

Time to give you the rest of the story here now Smile

Starting the day before, picked up the trailer at a frind after work and drove to the garage. Checked all that i could think of, and all clamps and stuff. Never been at a dyno before.. Anyways, got the car on the trailer, and drove to the truckfuel pump Smile

(called tax-free diesel here in Norway)

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Drove to the dynoguy (Jonus Racing) and got the car in the dyno. Can see that it marked its Territory again :p sometimes it just came a log of thick smoke :p

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And out in the free again, still alive!

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And the final was 398,5whp og 550wnm! Big Grin

First pull was just a test of how it was when I came, and it pushed 367whp and 580wnm at 2,6 bar, but at 7bar (!) backpressure... startet going over thing, and found a series of small preassure leaks in the wastegate controll. Some bad clamps, and even a melted push-fitting. Fixed alot here, and got the wastegate on a separate pressure circuit etc. This together drasticly lowered the backpressure, and lowered boostpressure and the NM. But we gained 13whp! Now we started to play with the turbos, but when we tried to give it more boost and get the turbos to play together the backpressure just took of again... Therefore we adjusteted the other way, and this worked quite well. pulls starts at hold on 2000rpm, and it hold about 0,4bar boost there. At 3000rpm the Hx30 gives 1bar boost, and here the bigboy Hx40 wakes up and take over the show. From here the HX40 does all the job, and the Hx30 actully is just a brake in the system. Finish pressure is 2,3bar boost. With all the "problems" I am very satisfied with the Power Big Grin

Here is a bad Picture of a even bader print of the curves

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Why the turbosetup dont worked as it should nobody really know, but it may all be because of my manyfolds that is very very comprimised because of the tight space... Anyways the car loose grip on the rear wheels of only pushing the peadal firm to the floor at 3.gear. It has enough Power :p

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Turbo - 05-30-2015

Serie/compond/ is not easy to get it "right" have you model or simulate for performance predict before? Have you looked a R2S system before?
How do you want them to work? one first, together and then second one? or do you want to run them together all time? can you please show the mathematics behind the choosing?
What boost pressure level is desirable for you?

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-30-2015

I dont know how to choose turbos, I have only got the turbos that should work together Smile

The goal is to have them working together all the time Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Turbo - 05-30-2015

what do you mean with -"I have only got the turbos that should work together"

and how much boost do you want?

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 05-31-2015

I have bougt the turbos from Petter, the Norwegian go-to-guy and Holset expert. He has set up the turbos. You follow? The setup is jused before, so it should have worked.

How much boost I have is actually the same, if it just have enough air to burn the diesel. Now it should have a bit more air Smile

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - raysorenson - 05-31-2015

It sounds like things work well, but not perfect. Data on hot and cold side pressure ratios after each turbo should tell the story.

Thanks for sharing the info with us. If you can't tell by reading this forum, there's intense interest in compounding here.

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Turbo - 06-01-2015

Yes I have understand you have bought them from Petter, but in a first way to analyse the working is to know how they in the first way was intended to work, I am in no way trying to criticise anything just want to understand the set up, when I do something, I look at how much do I need in air flow kg/s to get XX HP, what boost do I need for that happen, then turbo sizing and the way they work to get the air flow and the power characteristics, but I must have a original thinking of how set set up should work.
Like raysorenson suggested that information is good to know, but first you must know what was intended to analyse why the targets was not reached.

Great build and thanks for sharing with us

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Alcaid - 06-04-2015

The real "problem" is that this engine flows too much vs. the boost level that it is running so a sequential setup would have worked much better. My compound models where based on shitty flowing VAG engines so I didn't see this problem until I upgraded my model for these OM60* engines.

Looking at the numbers Stamsaas dynoed it is easy to see that what happens is that the HX30W ends up over the choke line, increasing the boost level on the HX40W will squeeze a bit more through it but what should have been done is to bypass the HX30W completely on both sides (sequential) or upgrade the HX30W so that it doesn't choke if keeping it pure compound.

- Sequential will spool as fast as now but give more HP up top
- Keeping it pure compound but upgrading the HX30W will also give more HP but spool will suffer somewhat

The HX30W can be updated from 73/44mm 6+6 compressor to a 73/50mm extended tip 11-blade billet wheel that I have on my compound build to easily avoid choke on the comp side and a 12cm turbine housing instead of the 6cm one to increase turbine choke flow capacity but low end spool will suffer somewhat. Part are plug and play if there is enough room to clear the bigger turbine housing. Flanges in and out of both housing will be placed the same way as the stock HX30W but turbine housing scroll is bigger.

RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Alcaid - 06-04-2015

HX30W-12cm with 73/50mm GTX style billet wheel with extended tips:

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RE: Om605 compound turbo build, my Corolla Ke70 tracktoy - Turbo - 06-04-2015

I do not understand much of this but what I do understand is there is no planing at all, how can there be success in the end!? Two turbo set up like this do not by accident going to work. If you want to do a compound set up you want a lot of boost in the first place, one turbo out of pressure ratio and faster spool. If you want a sequential set up these turbos is way to close to each other if you want good performance, just look at the R2S systems for example to start with.

Petter please for give me for saying it but if some one say to me -"I have bougt the turbos from Petter, the Norwegian go-to-guy and Holset expert" there has been putting a lot of trust in you and you answer -"My compound models where based on shitty flowing VAG engines so I didn't see this problem until I upgraded my model for these OM60* engines" well that make me speechless

And please do not make this into a flame war, that is not the point at all here, I think we can agree on that this is a great build and need some help for getting turbo to work properly,
stamsaas come up with what you want in performance so Peter can help you completing it! I do not know holset turbos that well for helping you out here, simply there is nothing to work on.

Simply I just wanted to know how you think in the set up and by discussing it some useful information to the members of this forum