OM 602 G Mercedes build for off-road racing

OM 602 G Mercedes build for off-road racing - Printable Version

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OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-01-2013

OM 602 rebuild for off-road with GTB 22/60 VZK. (and wastegate)

RE: OM 602 build for off-road - offroaddieselhu - 05-01-2013

Turbo assembling

RE: OM 602 G Mercedes build for off-road - Simpler=Better - 05-01-2013

Please report back on how the cast welding/brazing goes, and what your process/materials are. I'm planning on modifying a cast manifold one day and any advice would be great.

RE: OM 602 G Mercedes build for off-road - offroaddieselhu - 05-01-2013

First we tried with TIG (AWI). But the final solution was the hot metallisation welding (maybe it is not real english expression, but i tried to translate)

This is the metallisation hot welding on an other exhaust.

RE: OM 602 G Mercedes build for off-road - Simpler=Better - 05-01-2013

That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

RE: OM 602 G Mercedes build for off-road - offroaddieselhu - 05-01-2013

new oil pump 320 CDI

old oil pump

(05-01-2013, 03:18 PM)Simpler=Better That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

(05-01-2013, 04:38 PM)offroaddieselhu new oil pump 320 CDI

old oil pump

(05-01-2013, 03:18 PM)Simpler=Better That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

(05-01-2013, 03:18 PM)Simpler=Better That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

RE: OM 602 G Mercedes build for off-road - Simpler=Better - 05-01-2013

Beautiful!

RE: OM 602 G Mercedes build for off-road - tjts1 - 05-01-2013

That looks amazing but is it going to be able to support the weight of the turbo?

RE: OM 602 G Mercedes build for off-road - offroaddieselhu - 05-02-2013

(05-01-2013, 10:34 PM)tjts1 That looks amazing but is it going to be able to support the weight of the turbo?

I think it is easier than with iron fitting/adapter and screws. And the turbo will reach earlier the operating tempriture.

RE: OM 602 G Mercedes build for off-road - offroaddieselhu - 05-02-2013

BOSCH VE pump

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-02-2013

the sump

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-03-2013

G off-road racing

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-03-2013

intake Manifold

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-05-2013

I'm looking for a place

(05-05-2013, 02:22 PM)offroaddieselhu I'm looking for a place

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-05-2013

Previous OM602 series nozzle http://www.youtube.com/watch?v=VvfGjbNZgLM

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-06-2013

(05-05-2013, 03:32 PM)offroaddieselhu Previous OM602 series nozzle http://www.youtube.com/watch?v=VvfGjbNZgLM

http://www.youtube.com/watch?v=6WrhcuctF_Q

591 RACE

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-06-2013

OM602 GTB 2260+wastegate

(05-06-2013, 09:29 AM)offroaddieselhu OM602 GTB 2260+wastegate

RE: OM 602 G Mercedes build for off-road racing - Simpler=Better - 05-06-2013

It's so purdy!!!

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-06-2013

so you can be the easiest to solve

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-08-2013

an older OM602 turbo piping to error control http://www.youtube.com/watch?v=sn7jLQLrAsk

RE: OM 602 G Mercedes build for off-road racing - Duncansport - 05-09-2013

(05-06-2013, 05:36 AM)offroaddieselhu
(05-05-2013, 03:32 PM)offroaddieselhu Previous OM602 series nozzle http://www.youtube.com/watch?v=VvfGjbNZgLM

http://www.youtube.com/watch?v=6WrhcuctF_Q

591 RACE

Nice work your doing there, whats the scoop with the nozzles though? I wasn't aware there were different options for the 602, or what improvements they offer..

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-09-2013

(05-06-2013, 09:29 AM)offroaddieselhu OM602 GTB 2260+wastegate

(05-06-2013, 09:29 AM)offroaddieselhu OM602 GTB 2260+wastegate

(05-09-2013, 08:13 AM)Duncansport
(05-06-2013, 05:36 AM)offroaddieselhu
(05-05-2013, 03:32 PM)offroaddieselhu Previous OM602 series nozzle http://www.youtube.com/watch?v=VvfGjbNZgLM

http://www.youtube.com/watch?v=6WrhcuctF_Q

591 RACE

Nice work your doing there, whats the scoop with the nozzles though? I wasn't aware there were different options for the 602, or what improvements they offer..

Sorry, but what is your question with nozzles? ( I don't understand the english so well) Basically it has bigger hole.

RE: OM 602 G Mercedes build for off-road racing - Simpler=Better - 05-09-2013

What is the effect of using these nozzles?

Will they affect timing? Quantity of fuel injected?

What do they do, how did you decide to use them, anything like that so we can learn from your parts

(05-06-2013, 05:36 AM)offroaddieselhu
(05-05-2013, 03:32 PM)offroaddieselhu Previous OM602 series nozzle http://www.youtube.com/watch?v=VvfGjbNZgLM

http://www.youtube.com/watch?v=6WrhcuctF_Q

591 RACE

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-09-2013

(05-09-2013, 01:09 PM)Simpler=Better What is the effect of using these nozzles?

Will they affect timing? Quantity of fuel injected?

What do they do, how did you decide to use them, anything like that so we can learn from your parts

(05-06-2013, 05:36 AM)offroaddieselhu
(05-05-2013, 03:32 PM)offroaddieselhu Previous OM602 series nozzle http://www.youtube.com/watch?v=VvfGjbNZgLM

http://www.youtube.com/watch?v=6WrhcuctF_Q

591 RACE

do not want to get into a much more accurate fuel injection

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-09-2013

(05-09-2013, 01:29 PM)offroaddieselhu
(05-09-2013, 01:09 PM)Simpler=Better What is the effect of using these nozzles?

Will they affect timing? Quantity of fuel injected?

What do they do, how did you decide to use them, anything like that so we can learn from your parts

(05-06-2013, 05:36 AM)offroaddieselhu http://www.youtube.com/watch?v=6WrhcuctF_Q

591 RACE

do not want to get into a much more accurate fuel injection

VE want to lower loads operated pump. higher speed perfomance expect growth

RE: OM 602 G Mercedes build for off-road racing - raysorenson - 05-09-2013

What is your power goal with that turbo?

Are you utilizing the VGT part or just using the wastegate?

At what RPM's does it start to make boost?

I think this turbo would make a good street turbo but I've heard others say it's too small for a high-revving Mercedes diesel.

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-09-2013

(05-09-2013, 03:42 PM)raysorenson What is your power goal with that turbo?

Are you utilizing the VGT part or just using the wastegate?

At what RPM's does it start to make boost?

I think this turbo would make a good street turbo but I've heard others say it's too small for a high-revving Mercedes diesel.

I know that this turbo is small for this car. But for off-road it's starts to work at critic RPM. (aprox. 1500-1600) I think to use bigger turbo is not possible. I experienced that these engines with this options are not useble in cars (only in off-road or 4x4).

RE: OM 602 G Mercedes build for off-road racing - CRD4x4 - 05-09-2013

This is some beautiful work! I'm jealous, so keep it up!

RE: OM 602 G Mercedes build for off-road racing - raysorenson - 05-09-2013

(05-09-2013, 03:59 PM)offroaddieselhu I know that this turbo is small for this car. But for off-road it's starts to work at critic RPM. (aprox. 1500-1600) I think to use bigger turbo is not possible. I experienced that these engines with this options are not useble in cars (only in off-road or 4x4).

Hmmm.... I'm still not convinced it's too small for street. It makes 240hp on a low-rpm diesel with emission controls. If I could get 220hp out of a 603 and get good boost at 1500 rpm, my car would be very fun to drive with this turbo. I'm also considering using this turbo on a OM617 Toyota FJ40 with a 58.2:1 crawl ratio. If it makes any boost below 1500rpm with a 3.0L 617 it will be a great rock crawling turbo too.

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-10-2013

(05-09-2013, 08:56 PM)raysorenson
(05-09-2013, 03:59 PM)offroaddieselhu I know that this turbo is small for this car. But for off-road it's starts to work at critic RPM. (aprox. 1500-1600) I think to use bigger turbo is not possible. I experienced that these engines with this options are not useble in cars (only in off-road or 4x4).

Hmmm.... I'm still not convinced it's too small for street. It makes 240hp on a low-rpm diesel with emission controls. If I could get 220hp out of a 603 and get good boost at 1500 rpm, my car would be very fun to drive with this turbo. I'm also considering using this turbo on a OM617 Toyota FJ40 with a 58.2:1 crawl ratio. If it makes any boost below 1500rpm with a 3.0L 617 it will be a great rock crawling turbo too.

It could work well in OM 603, if the geometric options is good. I'm not specialist of pump (MW).
I work with VE pumps. It is possibly that with closed geometry it's blast the gear. Smile

If a rock crawling car would have place, I would put OM613 or in case of small place OM624, with any kind of geometric turbo.

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-10-2013

(05-01-2013, 04:38 PM)offroaddieselhu new oil pump 320 CDI

old oil pump

(05-01-2013, 03:18 PM)Simpler=Better That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

(05-01-2013, 04:38 PM)offroaddieselhu new oil pump 320 CDI

old oil pump

(05-01-2013, 03:18 PM)Simpler=Better That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

(05-01-2013, 03:18 PM)Simpler=Better That's weird as hell, but looks like it did the job!

Do you have any more photos of the assembly?

Is this the method:

http://www.youtube.com/watch?v=9mCfchnJ724

http://www.aws.org/wj/nov02/feature.html

http://reneuxit-thermal-spray.com/Thermal_Spray_or_Weld_.html

scarcity of space

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-14-2013

build

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-15-2013

VGT build

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-15-2013

(05-15-2013, 06:15 AM)offroaddieselhu VGT build

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-15-2013

vgt test https://www.youtube.com/watch?v=u74Ofbgjaoc https://www.youtube.com/edit?ns=1&feature=vm-privacy&video_id=8KzaMJkrWmg

RE: OM 602 G Mercedes build for off-road racing - larsalan - 05-15-2013

very nice

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-15-2013

(05-15-2013, 02:54 PM)larsalan very nice

RE: OM 602 G Mercedes build for off-road racing - Ksteen2 - 05-16-2013

looking good Wink

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-16-2013

ready for 1st start

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-20-2013

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/945791_509763172416833_951175316_n.jpg

(05-16-2013, 06:08 AM)offroaddieselhu ready for 1st start

(05-20-2013, 06:43 AM)offroaddieselhu https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/945791_509763172416833_951175316_n.jpg
(05-16-2013, 06:08 AM)offroaddieselhu ready for 1st start

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/945791_509763172416833_951175316_n.jpg

(05-20-2013, 06:43 AM)offroaddieselhu https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/945791_509763172416833_951175316_n.jpg
(05-16-2013, 06:08 AM)offroaddieselhu ready for 1st start

(05-20-2013, 06:43 AM)offroaddieselhu https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/945791_509763172416833_951175316_n.jpg
(05-16-2013, 06:08 AM)offroaddieselhu ready for 1st start

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash4/374306_451394988271648_88292426_n.jpg

RE: OM 602 G Mercedes build for off-road racing - Simpler=Better - 05-20-2013

It's aliiiiiiive!!!

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 05-20-2013

Big Grin

I think the setting are not so god. With big nozle too small the turbine. I have to optimalizate.

(05-20-2013, 08:01 AM)Simpler=Better It's aliiiiiiive!!!

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 06-02-2013

first test

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 06-03-2013

(06-02-2013, 04:33 PM)offroaddieselhu first test

RE: OM 602 G Mercedes build for off-road racing - Simpler=Better - 06-04-2013

As we say in 'murica, YEEEEEEHAAAAAAAAAAWWWWW!

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 06-04-2013

(06-04-2013, 09:06 AM)Simpler=Better As we say in 'murica, YEEEEEEHAAAAAAAAAAWWWWW!

It is far from the good! I haven't got any perfect turbo! It is too small!
Up to now it was small in low rpm, but recently it is small for hight rpm too.
offroaddieselhu

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 06-26-2013

(05-01-2013, 03:35 AM)offroaddieselhu OM 602 rebuild for off-road with GTB 22/60 VZK. (and wastegate);
and an other version OM602 engine with standard turbo and with UAZ body

[quote='offroaddieselhu' pid='52940' dateline='1372239345']
[quote='offroaddieselhu' pid='51237' dateline='1367397314']
OM 602 rebuild for off-road with GTB 22/60 VZK. (and wastegate);
and an other version OM602 engine with standard turbo and with UAZ body

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 06-29-2013

Mercedes G with UAZ body

RE: OM 602 G Mercedes build for off-road racing - offroaddieselhu - 07-02-2013

UAZ OM602 I don't like this car with original wastegate turbo

https://www.youtube.com/watch?v=6dQbo7nhXJk&list=UUybiLRDnKgtuoh8itXs2hZQ

RE: OM 602 G Mercedes build for off-road racing - mbz123 - 07-07-2013

(05-20-2013, 09:31 AM)offroaddieselhu I have to optimalizate.

Yes, I must do this too! Looking good on the build and following closely for the turbo infos.

THX

MBZ123