Om605 compound turbo build, my Corolla Ke70 tracktoy

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

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Om605 compound turbo build, my Corolla Ke70 tracktoy - Stamsaas - 03-03-2013

Hello all Smile

I have been registered here for a while, but havent written anything on here yet. Tought I could make a project tread for my car Smile

It startet with a 1980 Toyota Corolla Ke70, witch looked like this last season

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And when the winter came, the fun began

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Putting in a 1996 OM605 engine with 140kkm on its neck with a OM605 n/a pump that have been given the magic touch of Dieselmeken, 180cc with outside ALDA

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The engine its being coupled to a 717.435 5speed gearbox and a Spec stage 5 clutch is on its way. I allso have a 717.411 5speed in backup

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Jumping a bit fast forward, and here with radiator and cooler

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Have made a new exhaustmanifold put on it a a Holset HY35 nr9 and 3"downpipe

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If there is any interrest, I can continue the tread here Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - mantahead - 03-03-2013

awesome project, please continue. Big Grin

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - George3soccer - 03-03-2013

Please do. Sounds wonderful.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - willbhere4u - 03-03-2013

Nice take some videos of it running!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 03-03-2013

That manifold it great, I like your downpipe taper welding Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 03-04-2013

awesome builde Wink

are you going to Gatebil with it, when you are done??
keep up the good work Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - maxypriest - 03-04-2013

keep up the good work! :-)

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-04-2013

Thanks guys! Smile

Looks like I can continue to post here Smile

Videos will come later when getting closer to test drive Smile

I dont know about Gatebil Ksteen2, I live 10-15minutes from Rudskogen, so have been thinking about it, but not for drive, its too many clowns on the track :/

Can put up some more pics here, from other things

New front brakes

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Welding of coilovers

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Rollcage ready to be made

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new 15" wheels since the old 14" are to small to clear the new brakes

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BMW z4 brakediscs redrilled to fit 4x114,3

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And front coilovers put in, with shortened controlarmes to get more lock, and RCA spacers

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That is a quick resume, have been alot custom fabrication, since there is very little parts to get to this car, and to put a 605 in to it ;P

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 03-04-2013

I imagine that's tough to find parts for. Anything pre-mid-90s and people think it should be in a museum x_X

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 03-04-2013

Nice project! Cool to see that the OM engines is being used in many cars Smile

Maybe it`s the new Ford YB engine Big Grin

Looks like you got the same HY as i have. Don`t you need to turn the turbine housing so the pressure pipe don`t go right up in the hood? I guess the turbo on the RAM is mounted the same way as on the 606/605, with the exhaust flange towards the cyl.head.

- Håvard

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 03-05-2013

aha, Yes, you'r absolutly right about that, it is to much klown drivers, but it's manny more events here in norway to atend to Wink

you can propably atend to Mercedes entusiasten and tccn meet's Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 03-05-2013

Gatebil rudskogen is nice if you want to get drunk Wink

For driving its just fun for the people that have "status"..:/

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - willbhere4u - 03-05-2013

I like the wheels

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - EDH_Performance - 03-05-2013

(03-05-2013, 10:32 AM)HaavardPYA Gatebil rudskogen is nice if you want to get drunk For driving its just fun for the people that have "status"..:/

Haha, if you show up with a coalsmoking corolla that smokes porsche and other exclusive cars you get status right away Big Grin

Keep up the good work Alexander Wink

Great to have you on this forum as well!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 03-06-2013

Agreed EDH Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-06-2013

(03-04-2013, 02:32 PM)Simpler=Better I imagine that's tough to find parts for. Anything pre-mid-90s and people think it should be in a museum x_X

haha

maybe it should have been in a museeum, its getting rare Smile

But very much Corolla Ae86 parts fits over, but ther are very ekspensive, so then it have to be custom Wink

(03-04-2013, 04:24 PM)HaavardPYA Nice project! Cool to see that the OM engines is being used in many cars Maybe it`s the new Ford YB engine

Looks like you got the same HY as i have. Don`t you need to turn the turbine housing so the pressure pipe don`t go right up in the hood? I guess the turbo on the RAM is mounted the same way as on the 606/605, with the exhaust flange towards the cyl.head.

- Håvard

Dont know if this is a new "universal" engine, its quite big and heavy! it weights 4xtimes what the oem engine did i think, so its getting a heavy nose :p
Yes the HY is from a RAM, I got is for a nice price, thats why I have it. Will be fun to se how it works out with the engine Smile

Must turn the housing down, yes Smile

(03-05-2013, 03:21 AM)Ksteen2 aha, Yes, you'r absolutly right about that, it is to much klown drivers, but it's manny more events here in norway to atend to
you can propably atend to Mercedes entusiasten and tccn meet's

Yeah, I use to take my other car there, for the show and shine Smile

Have taken home 4 trophys the 4 last times Wink

hope I can use the car much this summer, lives close to the track, so have to have a car to use there Smile

(03-05-2013, 12:29 PM)willbhere4u I like the wheels

Thanks

(03-05-2013, 05:14 PM)EDH_Performance
(03-05-2013, 10:32 AM)HaavardPYA Gatebil rudskogen is nice if you want to get drunk For driving its just fun for the people that have "status"..:/

Haha, if you show up with a coalsmoking corolla that smokes porsche and other exclusive cars you get status right away

Keep up the good work Alexander Great to have you on this forum as well!

time will show, not sure if I want to drive there, but it would be the right place to get som "status" :p
Thanks Daniel! Just give me a call if you are in the area Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - jeemu - 03-11-2013

Nice project. That exhaust manifold collector is not that nice, why not do same time that good when doign it?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-11-2013

Time for å update here now Wink

Have got the wheel hub machined to fit in the new brakedisks, and fitted them with new wheelbearings

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and testfitted the calipers, must make adapter to them

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I have removed som asphaltmats (?) on the floor

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And I have modified the Merc pedalset to fit, clutch and brakepedals, and the corolla gas, slight modified

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not to much place between the pedals Wink

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and brakesylinder from Volvo 240 put in

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Todays work was to fasten the gearchanger, and start on the shifting. Got the adjustment fresh

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ready to measure

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Cut, and weld!

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gitting there Smile

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Click click Wink

(03-11-2013, 04:00 PM)jeemu Nice project. That exhaust manifold collector is not that nice, why not do same time that good when doign it?

Thanks Jeemu! Smile

You are a om605 "youtube-legend", have seen the most you have there Smile

I know, the collector is not the most optimal solution, but there is a quite tight fit in the enginebay! there is really not the space that there is in a merc Wink

I must make a new one anyway is I am going bigger turbo, so I think it will be good enough for this one Wink

Im not chasing the highest numbers, as I dont need them, the car weights under 1000kg Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 03-11-2013

I'm impressed! The side shifting stuff just seems so weird to me I'm used to truck gearboxes

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - erling66 - 03-16-2013

Hi This is a great project Wink

and I like your way of solving problems, the gear box needs room? you just cut out the metal that needs to be removed, problem solved Big Grin

Are you going to keep the Norwegian plates?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-16-2013

Thanks! Smile

Havent had anything with shifting mechanism to do before, so its learning-by-doing as the most on this car is. Its also a budget build, so there is quite mush custom fabrication!
Thanks Erling! hehe, but what to do? needed more room Wink

I have the plates, becuse its so much easier on trackdays with a car with plates Smile

Testet the new rim today, with the brakedisc on (this spaces the rim 6mm out, to ET-6)

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And time to stretch some tyres

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got just the stretch I wantet, not overstretched, but rounded edges to clear the arches

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My mate made flenges to the oil lines to the turbo...

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...while I cut out some new brackets

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measureing

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And welding! Big Grin

custom fitment!

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Caliper and disc on

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tight fit

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And wheel on with more camber and new brakes

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Just to do the same on the other side..

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 03-19-2013

god damn, nice work, awesome, it will be the coolest car att every meeting Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 03-19-2013

perfect rims and tire stretch!! Nice work on the homemade brackets there too!
Keep up the good work Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-19-2013

Thanks guys! Big Grin

Its fun to make custom parts and make it fit Wink

hope i can make get the car ready so I can get to any meetings :p
Got the Spec Stage 5 clutch today, but it was wrong size Sad

its 218mm, dont know how much it can take?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 03-20-2013

is it 2 or 3 plated?
if it's 2 plated it can take about 800nm i've heard Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-20-2013

Its single plate. Got info from Spec that i it was rated to 564nm, so it should be enough, but then I have to find a matching flywheel.. Smile

I also need a aluminium intake manifold, if anyone have one Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-25-2013

Got the radiator back today, and startet on the mounts for that and the intercooler. Its getting very tight!

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Had to move the radiator over to the left because of the dynamo was in the way

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How long will the oilpan live? ;p

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Hope to Get something done the next days Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - MFSuper90 - 03-25-2013

You people overseas get to have all the fun Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 03-26-2013

I think you should lift it a Inch or two, and then mount a skidd plate Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 03-26-2013

Don`t know how much space there is between the oilsump and the oilpump on the OM engines. But on the s38 i mounted in my Granada i had to cut down the oilsumps height and make it wider. I also mounted it straight so it needed to be flat instead of the original 20degrees or so. So to cut the pan maybe a good option Smile

But if the engine can be lifted that would be a solution. But then again, the weight will come higher up.

Keep up the good work! I admire all your custom solutions! Love this project Big Grin

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-30-2013

(03-25-2013, 09:21 PM)MFSuper90 You people overseas get to have all the fun

It doesent get anymore fun than what you make out of it Wink

(03-26-2013, 03:20 AM)Ksteen2 I think you should lift it a Inch or two, and then mount a skidd plate

Cant lift it anymore, have already lifted it quite much Big Grin

Can say, Im a bit low-addicted Big Grin

Think I have to make some kind of shield yes Wink

(03-26-2013, 03:44 AM)HaavardPYA Don`t know how much space there is between the oilsump and the oilpump on the OM engines. But on the s38 i mounted in my Granada i had to cut down the oilsumps height and make it wider. I also mounted it straight so it needed to be flat instead of the original 20degrees or so. So to cut the pan maybe a good option
But if the engine can be lifted that would be a solution. But then again, the weight will come higher up.

Keep up the good work! I admire all your custom solutions! Love this project

Dont think there is "enough" space, but that have been one alterantiv yes, to cut and lift the oilpan, and widen it instead. Cant lift the engine, already have to cut out some of the suports in the hood to close it ;p Thanks! Very litle parts that fits, så there is alot custom going on ;p

Had some hours in the garage yesterday again, and got the other side brake welded up Smile

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and I got the suprts for the radiator and cooler finish

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And one step further in modding the steering collum to fit with the Ke70 elektroics

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RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 03-31-2013

More customwork today, had to borrow 1cm of the main tube of the rollcage, to the steerings bearing

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and welded it together

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some adjustments to the steeringwheel boss

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and the custom brackets ready

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and splines adjusted

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And finish steering from Opel Corsa with elektric servo, Ke70 elektronics and Mercedes wheelboss

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needed a shaft joint in the rear end, so donation from the original

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cut

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and weld

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Just have to get the right hight Smile

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also finished the front suspension, so its ready to put the wight on the spring and see what happends :p

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 03-31-2013

Cut & weld, my favorite solution!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - raysorenson - 03-31-2013

Hmmm... I haven't thought of using the column mounted power steering units. I think there's one from an Escape/Kuga laying around somewhere at work. Thanks for the inspiration!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 04-02-2013

this build is turning into be a badass one, and you'r fantasy is genius :p
I need to hear that beast roar :p
and maybe ride shotgun just to see what it does :p

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 04-05-2013

(03-31-2013, 08:46 PM)Simpler=Better Cut & weld, my favorite solution!

Mine too, its cheap! Wink

(03-31-2013, 09:50 PM)raysorenson Hmmm... I haven't thought of using the column mounted power steering units. I think there's one from an Escape/Kuga laying around somewhere at work. Thanks for the inspiration!

Happy if I can be any inspiration! Smile

(04-02-2013, 03:13 AM)Ksteen2 this build is turning into be a badass one, and you'r fantasy is genius :p
I need to hear that beast roar :p
and maybe ride shotgun just to see what it does :p

hehe, thanks! :p Im really ready to start it soon. Yeah, just come and say hello if wee meets on a trackday Wink

More updates;

I started on the rear axle that I will use, from Volvo 240, and removed the shafts to get them redrilled to 4x114,3

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My friend who does this also tok the turbo manifold and downpipe to machine the flanges after welding Smile

the floor is comming together, and have made my way around the gear shifter

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Now it was time to get the engine out to finish the floor and engine bay Smile

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Engine and pump timed up
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vacumpump is on, and top cover is on Smile

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Im working all weekend, so not time to much now. Hoping to test startup soon Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 04-09-2013

Some more mounted on the engine Smile

New clips for the lines are ordered

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And got 2 new HX40 to my friend Big Grin

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The manifold and downpipe machined

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And test on the engine

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Whay oil are you guys running on your tuned engines and manuall trany? Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - hansebanger77 - 04-10-2013

Wow looking good. I use Mobile 1 5w40 on my 606.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 04-10-2013

I use Gulf Supreme superfleet xle 10w40 on my 606 Wink

this is awesome Wink

Is it a OM605.962 or a 912?? :p

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 04-10-2013

(04-10-2013, 01:31 AM)hansebanger77 Wow looking good. I use Mobile 1 5w40 on my 606.

Thanks

thanks for the tip, looks like several are using 5w40 oil so think I will try it too Smile

(04-10-2013, 02:23 AM)Ksteen2 I use Gulf Supreme superfleet xle 10w40 on my 606

this is awesome
Is it a OM605.962 or a 912?? :p

Thanks! Its a om605.960 Wink

OEM turboengine Smile

think it will last long with my powergoal Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 04-28-2013

Started the engine today! Big Grin

Happiness!! Big Grin

http://www.youtube.com/watch?v=ycOgy7cff4c&feature=player_embedded

http://www.youtube.com/watch?v=8Em1d_qoWWk&feature=player_embedded

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 04-29-2013

cool Wink

now it's just to put it down in the car and give it some gas Wink

"spenn clutch Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 04-29-2013

Yeah, really have to Get the Floor finish now, hope I can get something done on wednesday Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 04-29-2013

Yeah, let's hope that Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-02-2013

Floor is half finished now, will continue timorrow Smile

Not my strongest side this bodywelding..

Now, here are some more pics that I not have got up here..

Rear axle ready with new mashined hubs with 4x114,3 and new studs Smile

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Ready to be mounted, with copper gasket

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Exhausttemp fitting welded in

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And made the support for the manifold and turbo

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And some cleaning under the car

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REALLY looking forward to the first testdrive! Big Grin

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 05-03-2013

when it's that low on stands, you know it will be low on the ground Wink

get this car on the run Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - majesty78 - 05-06-2013

(03-16-2013, 08:46 PM)Stamsaas My mate made flenges to the oil lines to the turbo...

It's not clear to see on picture, but did you flip around 180º oil feed and oil return, so that return is up and feed is downside?

If so, this will not work for the turbo.... :-(

BR

Alex

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-06-2013

I`m a bit low addict Ksteen, so it have to be low Wink

The oilfeed and oil return is on its right places, the turbo is just rotated 180º so it is easyer to mount the return plug Smile

The floor is now finnished! Big Grin

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The floor is pianted black and the underside is sprayed with black bodymass, but was empty battery on the phone so no pics today of that. Time to get the engine and transmission ready Big Grin

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 05-06-2013

You are an inspiration to us all!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 05-07-2013

nice Wink

but you really need a bit biffier tranny, or is it a 2,3 16v tranny??