The build starts, 320 cdi with stand alone ecu, twin turbo

The build starts, 320 cdi with stand alone ecu, twin turbo - Printable Version

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+--- Thread: The build starts, 320 cdi with stand alone ecu, twin turbo (/showthread.php?tid=3189)

The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-20-2011

teaser pics, all details of the build will be posted...

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Palmer - 12-20-2011

Is that turbo of a FH12 Globetrotter by any chance? lol

Im looking forward to this Big Grin

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - majesty78 - 12-21-2011

I guess its a gtb2056vk from volvo application...

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - angryspartan - 12-21-2011

this is what its all about! cant wait to see this build!

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-21-2011

Yes, it's the gtb 2056 vk from volvo.

Powergoal is 400 HP, so 2 should do with acceptable spoolup

We start with standard compression ratio

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-23-2011

first header design
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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - olefejer - 12-23-2011

That's a Cool build you have going on there, witch controller are you going to use BOSCH ?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-25-2011

no, we are using our own controller, I'll post pics tomorrow.

final manifold design :

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-27-2011

our controller

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - INC - 12-27-2011

Please post details and price for this controler.

It`s NIRA?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-27-2011

(12-27-2011, 12:19 PM)INC Please post details and price for this controler.

It`s NIRA?

No, develloped & produced in Belgium : It manages as well common rail piezo engines, common rail inductive engines, and pump injectors or UIS injectors engines up to 6 cilinders.

People who want details pm me your email

Stainless steel came in for the manifolds, welding starts thursday

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - majesty78 - 12-27-2011

Shall this engine go into an W210 engine bay again?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-27-2011

(12-27-2011, 02:52 PM)majesty78 Shall this engine go into an W210 engine bay again?

No, I am building 2 that are going in a boat Smile

Why?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - majesty78 - 12-27-2011

Ok that's what confused me because with those exhaust manifolds it would cause clearence issues in engine bay I guess....

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 12-28-2011

(12-27-2011, 06:05 PM)majesty78 Ok that's what confused me because with those exhaust manifolds it would cause clearence issues in engine bay I guess....

Should be interesting to try, if you want I send you measurements

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-09-2012

flanges

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Almost done Smile

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Intercooler

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Anyone has used these china intercoolers? I want to use 2 of them on each engine...
They any good?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Captain America - 01-10-2012

(01-09-2012, 01:18 PM)diesel2fast4u Intercooler

Anyone has used these china intercoolers? I want to use 2 of them on each engine...
They any good?

I have one

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - HughF_UK - 01-10-2012

We use those coolers on a pair of marinised isuzu 1.7 turbo diesels - worked very well so far for 2 seasons...

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Alcaid - 01-10-2012

Small mistake earlier in this thread, this is not a GTB2056VK turbo, it's the GTB2056VL with a lower trim compressor wheel compared to the VKs.

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-10-2012

@ Hugh , I wonder if they are big enough for +400 HP, otherwise I would use 2 on each engine...

@ Alcaid , you are right & they are water cooled

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-11-2012

injector driver & ECU

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - antonmies - 01-11-2012

one ic manufacturer in china told me that those w/a intercoolers couldn't take seawater...I guess it's the brazing material they use in manufacturing or he was being cautious.

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - yankneck696 - 01-11-2012

(01-11-2012, 07:44 AM)antonmies one ic manufacturer in china told me that those w/a intercoolers couldn't take seawater...I guess it's the brazing material they use in manufacturing or he was being cautious.

The saltwater MUST be run through a brass/bronze heat exchanger to cool antifreeze/water mixture. There MUST also be zinc sacrificial anodes in the saltwater portion. Then, you can use the coolant to cool the charge air. If used in fresh water, you can "get by" with this setup, but MUST fully examine the intercoler EACH time after it is run !!! That would necessitate an inspection plate & pressure checking/vacuum checking each outing. There are many marine intercoolers that are designed for marine/saltwater use that remove the loss of 2 transfer mediums.

When you use salt water (or anything but distilled water to a point) you WILL have electrolysis between dissimilar metals. That will corrode & eventually lead to porosity of the intercooler & eventual engine damage.

I work on marine engines for a living & see all too commonly that when the Zinc annodes are not replaced on a yearly basis that failure is a certainty.

If I were to use a W/A intercooler, I would surely use a couple zinc sacrificial anodes along with antifreeze/distilled water to help ensure longevity. Also, replacing the sacrificial anodes (even at West Marine prices of under $10.00) on a 6 month schedule (unless proven to be over 75% remaining after said time, then up to a year) MANDATORY for longevity.

Any questions, feel free to ask or PM me...

Ed

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-12-2012

only messed up 2 90° before getting it right

I don't like the metal work Sad

2morrow more cutting & welding ...

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-14-2012

it always looks easy ...

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-16-2012

manifold welding after alot of cutting Sad

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-16-2012

Senders
Map
2 x EGT
2 x EMP
Lambda

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Back turbo manifold

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-17-2012

Started the intake manifold, EGR Confused

Cut the original manifold & took out the swirl valves

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-18-2012

I am not quitting my day job, but getting the hang of it Smile

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Captain America - 01-19-2012

Looking much better! Smile

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-19-2012

intercooler design

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have some nice info on cdi injectors

1350bar Standard OM 613 injectors tested at 1600bar:

2000 injections 1100 ms = 117gr

With AMG nozzle at 1600 bar:

2000 injections 1100 ms = 204gr Smile

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - majesty78 - 01-20-2012

With 90mg/stroke you get about 100Nm per cylinder ;-)

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-20-2012

[quote='majesty78' pid='37727' dateline='1327038790']
With 90mg/stroke you get about 100Nm per cylinder ;-)
Well... we decided to put the nozzles in & see what is going to happin on the dyno....

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-21-2012

intake

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Rub87 - 01-21-2012

Looking good.. friend of me who works regulary on jetskis also said that if the anode if missing its a matter of days in seawater.. also for non salt water he said it would be mandatory with these alu cores..

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-24-2012

new vs old high pressure pump

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Rub87 - 01-25-2012

I've did some reading about the mods done to these pump, and it seems the US companies are asking up to 1000$ for some really basic mods, which usually are ported feedpump and metering valve.. I didnt found a proof they use bigger bore plunjers or difference E-shaft for more lift

I think this is the L110 pump, meaning leftturning 1100mm³ theoretical displacement per pump revolution

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - majesty78 - 01-25-2012

Hy Ruben, nice to meet you over here :-)

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Rub87 - 01-25-2012

Hi Alex, also nice to meet you over here, how's your new compressorwheel doing?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - zeeman - 01-29-2012

I am using the same engine a 2006 in a Street Rod project and need a stand alone computer to make it work, were did you gets yours? I also have a flywheel and bellhousing if you still need them. Is there anyway to use the stock computer?

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-29-2012

(01-29-2012, 12:57 AM)zeeman I am using the same engine a 2006 in a Street Rod project and need a stand alone computer to make it work, were did you gets yours? I also have a flywheel and bellhousing if you still need them. Is there anyway to use the stock computer?

Stock computer is in my opinion impossible because you would need a bosch wizard to turn off all things in the ECU you don't use in your car that will put the engine in Limp mode.
With EDC15 it was doable but not with EDC16, on top of that you can't run electronic VNT or VGT turbo's with the EDC15.

Pm me your email address

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - diesel2fast4u - 01-30-2012

did some work today

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Cut the intercoolers (thanks Joe)

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Core

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Welded :

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Intake ready for welding :

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Turbo mock up

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RE: The build starts, 320 cdi with stand alone ecu, twin turbo - toomanydiesels - 02-11-2012

I really hope someone corrects me on this, but I absolutely have to mention something.

What a great project. What wonderful results.

I did, however, notice something that set me wondering.

When building headers, the weld really matters and more welding is generally worse than less welding because of fatigue cracking.

I have always, ALWAYS seen, and been told, a header is welded on the gasket side of the flange. It is never welded on both sides of the flange. The single weld on the gasket side (against the engine block) is then dressed down smooth and the outboard side of the flange is left unwelded.

Those that do weld the outboard side of the flange invariably have a very good looking and stout header -- except it soon cracks miserably from fatigue and vibration.

Now, does that apply here? I can't say. But it does apply in gassers of just about every size.

And I'm certainly not trying to stall your wonderful project. And I'm not saying you will experience abysmal failures. And I'm not saying to yank all that apart and rebuild it, Heavens No! Everything might be just fine.

But if you end up faced with a mysterious cracking problem, you might look into that because it seems to always happen.

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Boatbuilder - 04-23-2012

Hi, nice project. I have two similar engines in my boat. next friday in the sea for final testing. Runs with Bravo III and watercooled exhaust
manifold, watercooled intercooler, oil cooler, and power steering oil cooler . Run with a modified Bosch original ECU. Lot of work avoiding limp mode , but ok now.
I am also running with a heavy flywheel.
Your project are with exhaust direct into the two turboes and dry exhaust after turboes. In my opinion that should create a lot of heat
in the engine room and where are you routing the seawater outlet ?

These 6 cyl engine runs very smooth and well balanced.

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Theturbodave - 05-17-2012

Good work man. I had one question on the twin turbo manifolds i have done you have to run a balance tube between manifold or a surge will happen between the turbo due to firing order of the cylinder (2 cylinders fire in one manifold while other one only one fires and the it switchs). Is there something different on the diesel engine. This happens at light loads part throttle. Just asking, keep up the good work u have some good skills.

RE: The build starts, 320 cdi with stand alone ecu, twin turbo - Lucian189 - 09-05-2014

Awsome! any updates??