Norwegian OM606 build

STD Other Projects Norwegian OM606 build

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EDH_Performance

Holset

537

12-25-2011, 09:43 PM #1

I fitted an Eaton m90 compressor and tuned the stock 5.5mm pump to max, and got out around 170ish hp (dyno papers will come)

This worked very well, and drove with this mod for almost 6monts!
But 170+hp wasn`t enough Smile

So I bought an shorblock OM606.962 from Erling66 on this forum. This engine had 2 badly bent rods, and 1 minor bent rod. So i bought 6 H-profile rods from Sten Parner Motor form sweden. All gaskets, pistonrings+++ was bought. So lets get on with the pictures Smile

Pictures from the first build:

[Image: P1060049.jpg]

The setup now is turbo+compressor, and a 7.5mm M-Pump built by Dieselmeken.
Pictures from current build

[Image: IMG_3173.jpg]

Who said turbocharging was easy???? Smile

N/A vs Custom turbo manifold

[Image: IMG_3285.jpg]

All pistons, rods where weight balanced to +-0.05grams
Piston rings was also gapped to right measurment.

[Image: IMG_3296.jpg]

Custom flywheel made from a stock om604 motor, with an 6 puck sinterdisk and Sachs racing Bmw e34 preassure plate.

[Image: IMG_3298.jpg]

[/align]

Main-bearing girdle was made...

[Image: IMG_3342.jpg]

In these days the head is ported! A lot can be done to the channels, speacily the exhaust side Smile

Pictures will come Smile

Stay tuned

This post was last modified: 12-25-2011, 10:03 PM by EDH_Performance.

EDH_Performance

12-25-2011, 09:43 PM #1

Hi guys,

I have posted a few photos of my project here in different treads.
But here I will post all my photos of my high hp OM606 build.
The engine started out as an .910 engine with a stock 5.5mm M pump, and some tweaking was done too it along the way.
The car I started with was an MB w201 2.0D 4-speed 1993 mod.

I drove it a while with the stock Om606.910 engine, it worked very well, but 136hp wasn`t enough Smile
I fitted an Eaton m90 compressor and tuned the stock 5.5mm pump to max, and got out around 170ish hp (dyno papers will come)

This worked very well, and drove with this mod for almost 6monts!
But 170+hp wasn`t enough Smile

So I bought an shorblock OM606.962 from Erling66 on this forum. This engine had 2 badly bent rods, and 1 minor bent rod. So i bought 6 H-profile rods from Sten Parner Motor form sweden. All gaskets, pistonrings+++ was bought. So lets get on with the pictures Smile

Pictures from the first build:

[Image: P1060049.jpg]
[Image: IMG_2419.jpg]
[Image: IMG_0767.jpg]
[Image: IMG_0773.jpg]
[Image: IMG_0779.jpg]
[Image: IMG_0781.jpg]
[Image: IMG_0796.jpg]
[Image: IMG_0810.jpg]

The setup now is turbo+compressor, and a 7.5mm M-Pump built by Dieselmeken.
Pictures from current build

[Image: IMG_3173.jpg]

Who said turbocharging was easy???? Smile

N/A vs Custom turbo manifold

[Image: IMG_3285.jpg]

All pistons, rods where weight balanced to +-0.05grams
Piston rings was also gapped to right measurment.

[Image: IMG_3296.jpg]

Custom flywheel made from a stock om604 motor, with an 6 puck sinterdisk and Sachs racing Bmw e34 preassure plate.

[Image: IMG_3298.jpg]

[/align]

Main-bearing girdle was made...

[Image: IMG_3342.jpg]

In these days the head is ported! A lot can be done to the channels, speacily the exhaust side Smile

Pictures will come Smile

Stay tuned

willbhere4u

Six in a row make her go!

2,507

12-25-2011, 10:55 PM #2

Very impressive! Whats that bent rod from?

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

willbhere4u

12-25-2011, 10:55 PM #2

Very impressive! Whats that bent rod from?

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

George3soccer

Holset

373

12-26-2011, 05:39 AM #3

looks like allot of fun, congrats, and keep up the fun build.

Mb 1984 w201 om603 swap.
Mb 1986 w201 190E 2.3-16v
Mb 2004 w203 C230k

George3soccer

12-26-2011, 05:39 AM #3

looks like allot of fun, congrats, and keep up the fun build.

Mb 1984 w201 om603 swap.
Mb 1986 w201 190E 2.3-16v
Mb 2004 w203 C230k

EDH_Performance

Holset

537

12-26-2011, 07:53 AM #4

(12-25-2011, 10:55 PM)willbhere4u Very impressive! Whats that bent rod from?

Waterlock

EDH_Performance

12-26-2011, 07:53 AM #4

(12-25-2011, 10:55 PM)willbhere4u Very impressive! Whats that bent rod from?

Waterlock

willbhere4u

Six in a row make her go!

2,507

12-26-2011, 10:17 AM #5

make sure you take some good videos of it running

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

willbhere4u

12-26-2011, 10:17 AM #5

make sure you take some good videos of it running

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

jeemu

"some people do, some people talk."

457

12-26-2011, 12:19 PM #6

Sten Parner rods with 28mm upper bush Huh

OM605 600hp diesel drag car build with BMW E30 chassis

jeemu

12-26-2011, 12:19 PM #6

Sten Parner rods with 28mm upper bush Huh

OM605 600hp diesel drag car build with BMW E30 chassis

Riverstick

GT2256V

114

12-27-2011, 04:21 AM #7

Great thread...great pics...keep it rolling

" It is far easier to get forgiveness rather than permission"

Riverstick

12-27-2011, 04:21 AM #7

Great thread...great pics...keep it rolling

" It is far easier to get forgiveness rather than permission"

EDH_Performance

Holset

537

12-27-2011, 08:58 AM #8

(12-26-2011, 12:19 PM)jeemu Sten Parner rods with 28mm upper bush

Turbo pistons requires 28mm pin yes Wink

They was pretty thin in the top! Do you have any bad experience with them?

This post was last modified: 12-27-2011, 08:59 AM by EDH_Performance.

EDH_Performance

12-27-2011, 08:58 AM #8

(12-26-2011, 12:19 PM)jeemu Sten Parner rods with 28mm upper bush

Turbo pistons requires 28mm pin yes Wink

They was pretty thin in the top! Do you have any bad experience with them?

erling66

SuperDieselVan

294

12-27-2011, 01:33 PM #9

Hmmm, looks like it is going to be tough for me to get the strongest 606 in Southern Norway Dodgy

But that is cool Smile

Why did you weld the back side of your flywheel?
and what turbo is that?

erling66

12-27-2011, 01:33 PM #9

Hmmm, looks like it is going to be tough for me to get the strongest 606 in Southern Norway Dodgy But that is cool Smile
Why did you weld the back side of your flywheel?
and what turbo is that?

EDH_Performance

Holset

537

12-27-2011, 03:09 PM #10

(12-27-2011, 01:33 PM)erling66 Hmmm, looks like it is going to be tough for me to get the strongest 606 in Southern Norway But that is cool
Why did you weld the back side of your flywheel?
and what turbo is that?

Haha, who knows Erling...Time will show!
I had to weld the startertooths to the flywheel bacuase I had to take away so much material, that the startertooths would fall off if haden`t Smile

The turbo is a T70 super, similar to Garrett T-61.. I have a bigger turbo as well, but hope this will do for now Wink

This post was last modified: 12-27-2011, 03:11 PM by EDH_Performance.

EDH_Performance

12-27-2011, 03:09 PM #10

(12-27-2011, 01:33 PM)erling66 Hmmm, looks like it is going to be tough for me to get the strongest 606 in Southern Norway But that is cool
Why did you weld the back side of your flywheel?
and what turbo is that?

Haha, who knows Erling...Time will show!
I had to weld the startertooths to the flywheel bacuase I had to take away so much material, that the startertooths would fall off if haden`t Smile

The turbo is a T70 super, similar to Garrett T-61.. I have a bigger turbo as well, but hope this will do for now Wink

bad3gakk

om605 - kkk27 - w124

52

12-27-2011, 11:47 PM #11

A buddy of mine ran his 606 with hx40 (19ccm turbine) and a 3" downpipe.. that created too much backpressure.. he only got 2,2bars manifoil pressure.. another buddie of mine ran his 603 with 0,5mm smaller pump elements, a little smaller turbine, and 4" downpipe and exhaust, and got 3,5+ bars...
You might concider building a bigger DP... i got myself 2m of straight 4", and 2 mandrel bendt 90's for christmas Smile

it turned out to be a beatiful peice of metal in the end, and will help my 605 sing beautiful serenades Tongue

bad3gakk

12-27-2011, 11:47 PM #11

jeemu

"some people do, some people talk."

457

12-28-2011, 05:30 AM #12

Hope those rods hold up. Piston+pin is wery heavy Smile

On my 605 i had 2.7-3.2bar boost and back pressure with 3.5" DP was 1.8-2.2bar

This post was last modified: 12-28-2011, 05:31 AM by jeemu.

OM605 600hp diesel drag car build with BMW E30 chassis

jeemu

12-28-2011, 05:30 AM #12

Hope those rods hold up. Piston+pin is wery heavy Smile
On my 605 i had 2.7-3.2bar boost and back pressure with 3.5" DP was 1.8-2.2bar

OM605 600hp diesel drag car build with BMW E30 chassis

EDH_Performance

Holset

537

12-28-2011, 06:38 AM #13

(12-27-2011, 11:47 PM)bad3gakk A buddy of mine ran his 606 with hx40 (19ccm turbine) and a 3" downpipe.. that created too much backpressure.. he only got 2,2bars manifoil pressure.. another buddie of mine ran his 603 with 0,5mm smaller pump elements, a little smaller turbine, and 4" downpipe and exhaust, and got 3,5+ bars...
You might concider building a bigger DP... i got myself 2m of straight 4", and 2 mandrel bendt 90's for christmas it turned out to be a beatiful peice of metal in the end, and will help my 605 sing beautiful serenades

Sounds nice, how many hp did you buddy`s OM606 make?
It is plenty room for a bigger DP Smile

But i will meausure backpreassure first...

(12-28-2011, 05:30 AM)jeemu Hope those rods hold up. Piston+pin is wery heavy
On my 605 i had 2.7-3.2bar boost and back pressure with 3.5" DP was 1.8-2.2bar

I was a bit afraid for that to happen...The piston are way more heavier than the N/A piston Smile

But the rod are strong the other way, so we have to see if it holds together... If it breaks, then I will buy some new stock rods!

This post was last modified: 12-28-2011, 06:43 AM by EDH_Performance.

EDH_Performance

12-28-2011, 06:38 AM #13

(12-27-2011, 11:47 PM)bad3gakk A buddy of mine ran his 606 with hx40 (19ccm turbine) and a 3" downpipe.. that created too much backpressure.. he only got 2,2bars manifoil pressure.. another buddie of mine ran his 603 with 0,5mm smaller pump elements, a little smaller turbine, and 4" downpipe and exhaust, and got 3,5+ bars...
You might concider building a bigger DP... i got myself 2m of straight 4", and 2 mandrel bendt 90's for christmas it turned out to be a beatiful peice of metal in the end, and will help my 605 sing beautiful serenades

Sounds nice, how many hp did you buddy`s OM606 make?
It is plenty room for a bigger DP Smile

But i will meausure backpreassure first...

(12-28-2011, 05:30 AM)jeemu Hope those rods hold up. Piston+pin is wery heavy
On my 605 i had 2.7-3.2bar boost and back pressure with 3.5" DP was 1.8-2.2bar

I was a bit afraid for that to happen...The piston are way more heavier than the N/A piston Smile

But the rod are strong the other way, so we have to see if it holds together... If it breaks, then I will buy some new stock rods!

barrote

Superturbo

1,627

12-28-2011, 07:27 AM #14

Hello,
Silly question but, did u balance the camshaft? cause i did not understood why u weigh piston and rods. other question can´t u guys find steel crown piston´s for these engines? i also want to do some changes of the inside but, thing is camshaft balance is difficult around here, so as some inside custom parts.
regards

FD,
Powered by tractor fuel

barrote

12-28-2011, 07:27 AM #14

FD,
Powered by tractor fuel

EDH_Performance

Holset

537

12-28-2011, 08:21 AM #15

(12-28-2011, 07:27 AM)barrote Hello,
Silly question but, did u balance the camshaft? cause i did not understood why u weigh piston and rods. other question can´t u guys find steel crown piston´s for these engines? i also want to do some changes of the inside but, thing is camshaft balance is difficult around here, so as some inside custom parts.
regards

I guess you meen crankshaft? I have not balanced it, only the flywheel. I wheight-balanced the pistons and rods because There was a big difference in weight...

This post was last modified: 12-28-2011, 08:22 AM by EDH_Performance.

EDH_Performance

12-28-2011, 08:21 AM #15

(12-28-2011, 07:27 AM)barrote Hello,
Silly question but, did u balance the camshaft? cause i did not understood why u weigh piston and rods. other question can´t u guys find steel crown piston´s for these engines? i also want to do some changes of the inside but, thing is camshaft balance is difficult around here, so as some inside custom parts.
regards

I guess you meen crankshaft? I have not balanced it, only the flywheel. I wheight-balanced the pistons and rods because There was a big difference in weight...

barrote

Superturbo

1,627

12-28-2011, 09:17 AM #16

yep i meant crankshaft Smile

. according to papers there´s no reason to balance crankshaft to rod/piston dynamic forces, unless u want to gain real RPM, and engine smoothness (alias better rev performance) but since u did it outside, don't think it would have too much deterioration vibrations.
i´m curios about the pistons, how can u prevent them from melting? taking account u guys use stock ones?

FD,
Powered by tractor fuel

barrote

12-28-2011, 09:17 AM #16

yep i meant crankshaft Smile . according to papers there´s no reason to balance crankshaft to rod/piston dynamic forces, unless u want to gain real RPM, and engine smoothness (alias better rev performance) but since u did it outside, don't think it would have too much deterioration vibrations.
i´m curios about the pistons, how can u prevent them from melting? taking account u guys use stock ones?

FD,
Powered by tractor fuel

jeemu

"some people do, some people talk."

457

12-28-2011, 02:52 PM #17

If original pistons melt you have done something really wrong Smile

OM605 600hp diesel drag car build with BMW E30 chassis

jeemu

12-28-2011, 02:52 PM #17

If original pistons melt you have done something really wrong Smile

OM605 600hp diesel drag car build with BMW E30 chassis

EDH_Performance

Holset

537

12-28-2011, 06:03 PM #18

(12-28-2011, 02:52 PM)jeemu If original pistons melt you have done something really wrong

Haha! So true Jeemu Smile

They seems to be very tough Big Grin

EDH_Performance

12-28-2011, 06:03 PM #18

(12-28-2011, 02:52 PM)jeemu If original pistons melt you have done something really wrong

Haha! So true Jeemu Smile

They seems to be very tough Big Grin

EDH_Performance

Holset

537

12-28-2011, 08:23 PM #19

I have ported the head these days, and this is just a test how the exhaust would look like Smile

EDH_Performance

12-28-2011, 08:23 PM #19

I have ported the head these days, and this is just a test how the exhaust would look like Smile

[Image: IMG_3416.jpg]
[Image: IMG_3415.jpg]

[Image: IMG_3421.jpg]
[Image: IMG_3420.jpg]

erling66

SuperDieselVan

294

12-29-2011, 05:12 AM #20

What about the space between the 2 exhaust ports Huh

My guess is that it creates turbulence and reduced flow. But I have not seen anyone build a manifold with metal to fill the space so maybe it is not a big deal?

erling66

12-29-2011, 05:12 AM #20

What about the space between the 2 exhaust ports Huh
My guess is that it creates turbulence and reduced flow. But I have not seen anyone build a manifold with metal to fill the space so maybe it is not a big deal?

jeemu

"some people do, some people talk."

457

12-29-2011, 05:56 AM #21

Exhaust side be careful, not now remember but there is weak spot on one channel. You can see it at there is ääh how i say, not know word.
Tunnel go side that exhaust channel. Taht can be port thru there.

OM605 600hp diesel drag car build with BMW E30 chassis

jeemu

12-29-2011, 05:56 AM #21

OM605 600hp diesel drag car build with BMW E30 chassis

EDH_Performance

Holset

537

12-29-2011, 08:53 AM #22

(12-29-2011, 05:56 AM)jeemu Exhaust side be careful, not now remember but there is weak spot on one channel. You can see it at there is ääh how i say, not know word.
Tunnel go side that exhaust channel. Taht can be port thru there.

Thank you jeemu, i`ve just ported on cyl Smile

Will be carefull on the other, snd look for thin spots Smile

EDH_Performance

12-29-2011, 08:53 AM #22

(12-29-2011, 05:56 AM)jeemu Exhaust side be careful, not now remember but there is weak spot on one channel. You can see it at there is ääh how i say, not know word.
Tunnel go side that exhaust channel. Taht can be port thru there.

Thank you jeemu, i`ve just ported on cyl Smile

Will be carefull on the other, snd look for thin spots Smile

EDH_Performance

Holset

537

01-18-2012, 01:06 PM #23

The head has been ported now, resurfaced and cleaned Smile

A new and longer belt was fitted, and the routing has also been altered...A servopump has also been fitted!
[Image: IMG_3682.jpg]

Clutchplate is an 6-puck 240mm without center.
[Image: IMG_3668.jpg]

The block turned out really good Smile

With new H-profile rods and a maingirdle for the mainbearings...I have also fitted a 4 layer mls headgasket Smile

The motor runs really nice now and i have driven it many miles now! Big Grin

Took it out on a ice race this weekend, everything worked like a treat Smile

First start up video Smile

It smokes alot because we couldn`t glow all the glowplugs!

Here is some video from the track Smile

This post was last modified: 01-18-2012, 01:13 PM by EDH_Performance.

EDH_Performance

01-18-2012, 01:06 PM #23

The head has been ported now, resurfaced and cleaned Smile
[Image: IMG_3650-1.jpg]
[Image: IMG_3680.jpg]
[Image: IMG_3679.jpg]
[Image: IMG_3677.jpg]
[Image: IMG_3675.jpg]

A new and longer belt was fitted, and the routing has also been altered...A servopump has also been fitted!
[Image: IMG_3682.jpg]

Clutchplate is an 6-puck 240mm without center.
[Image: IMG_3668.jpg]
[Image: IMG_3669.jpg]

The block turned out really good Smile

With new H-profile rods and a maingirdle for the mainbearings...I have also fitted a 4 layer mls headgasket Smile

The motor runs really nice now and i have driven it many miles now! Big Grin

Took it out on a ice race this weekend, everything worked like a treat Smile

First start up video Smile

It smokes alot because we couldn`t glow all the glowplugs!

Here is some video from the track Smile

HughF_UK

GT2256V

140

01-18-2012, 04:02 PM #24

Can I ask where you got that clutch puck from?

I Like Smile

HughF_UK

01-18-2012, 04:02 PM #24

Can I ask where you got that clutch puck from?

I Like Smile

EDH_Performance

Holset

537

01-18-2012, 05:06 PM #25

(01-18-2012, 04:02 PM)HughF_UK Can I ask where you got that clutch puck from?

I Like

http://shop.klracing.se/sv/artiklar/kopp...index.html

EDH_Performance

01-18-2012, 05:06 PM #25

(01-18-2012, 04:02 PM)HughF_UK Can I ask where you got that clutch puck from?

I Like

http://shop.klracing.se/sv/artiklar/kopp...index.html

erling66

SuperDieselVan

294

01-19-2012, 09:24 AM #26

Great to see that the Mighty 190 is running again Smile

and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms Big Grin

erling66

01-19-2012, 09:24 AM #26

Great to see that the Mighty 190 is running again Smile and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms Big Grin

EDH_Performance

Holset

537

01-19-2012, 01:54 PM #27

(01-19-2012, 09:24 AM)erling66 Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

It was a good block and pistons Erling! Smile

I had to have servo on the ice track, it was to hard to steer fast Wink

EDH_Performance

01-19-2012, 01:54 PM #27

(01-19-2012, 09:24 AM)erling66 Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

It was a good block and pistons Erling! Smile

I had to have servo on the ice track, it was to hard to steer fast Wink

erling66

SuperDieselVan

294

01-19-2012, 03:36 PM #28

(01-19-2012, 01:54 PM)EDH_Performance
(01-19-2012, 09:24 AM)erling66 Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

It was a good block and pistons Erling! I had to have servo on the ice track, it was to hard to steer fast

I know, I am just having fun Smile

You are a fast worker, I am surprised to see the car running already. What's next, install the turbo, intercooler and get a pump with bigger elements? Tomniks 7,5mm or Myna?

This post was last modified: 01-19-2012, 04:02 PM by erling66.

erling66

01-19-2012, 03:36 PM #28

(01-19-2012, 01:54 PM)EDH_Performance
(01-19-2012, 09:24 AM)erling66 Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

It was a good block and pistons Erling! I had to have servo on the ice track, it was to hard to steer fast

I know, I am just having fun Smile

You are a fast worker, I am surprised to see the car running already. What's next, install the turbo, intercooler and get a pump with bigger elements? Tomniks 7,5mm or Myna?

EDH_Performance

Holset

537

01-19-2012, 04:24 PM #29

The custom manifold and turbo is good to go!
I dont trust the germans or the finnish Smile

HAHA...So Gøran aka Dieselmeken is building one for me Smile

= 7.5mm elements and lightened gouvenor!
I will fit the header, turbo and intercooler very soon...Mr Eaton is very noisy, so the intercooler+gate will help him be a bit more quiet Wink

EDH_Performance

01-19-2012, 04:24 PM #29

The custom manifold and turbo is good to go!
I dont trust the germans or the finnish Smile HAHA...So Gøran aka Dieselmeken is building one for me Smile = 7.5mm elements and lightened gouvenor!
I will fit the header, turbo and intercooler very soon...Mr Eaton is very noisy, so the intercooler+gate will help him be a bit more quiet Wink

EDH_Performance

Holset

537

01-26-2012, 07:29 PM #30

Intercooler has been fitted aswell as a big oilcooler:

[Image: IMG_3705.jpg]

All was painted black for Ultra Stealth Look Smile

The valve that is going to bypass the Compressor is made:

[Image: IMG_3730.jpg]

This post was last modified: 01-26-2012, 07:30 PM by EDH_Performance.

EDH_Performance

01-26-2012, 07:29 PM #30

Intercooler has been fitted aswell as a big oilcooler:

[Image: IMG_3705.jpg]
[Image: IMG_3707.jpg]
[Image: IMG_3710.jpg]
[Image: IMG_3715.jpg]
[Image: IMG_3718.jpg]
[Image: IMG_3726.jpg]

All was painted black for Ultra Stealth Look Smile

The valve that is going to bypass the Compressor is made:

[Image: IMG_3730.jpg]

EDH_Performance

Holset

537

01-29-2012, 10:13 AM #31

Now the turbo is mounted, and all works very good! Fantastic sound and
the car is awsome to drive!

Intercooler and pipes:

[Image: IMG_3755.jpg]

Turbo and header:

[Image: IMG_3757.jpg]

Now is it just up to Gøran aka Dieselmeken, to supply me with some go-go juice!!!!!!!!!!!!!!! Big Grin

EDH_Performance

01-29-2012, 10:13 AM #31

Now the turbo is mounted, and all works very good! Fantastic sound and
the car is awsome to drive!

Intercooler and pipes:

[Image: IMG_3755.jpg]
[Image: IMG_3753.jpg]
[Image: IMG_3751.jpg]

Turbo and header:

[Image: IMG_3757.jpg]
[Image: IMG_3760.jpg]
[Image: IMG_3763.jpg]
[Image: IMG_3764.jpg]
[Image: IMG_3765.jpg]
[Image: IMG_3767.jpg]

Now is it just up to Gøran aka Dieselmeken, to supply me with some go-go juice!!!!!!!!!!!!!!! Big Grin

majesty78

GT2559V

226

01-29-2012, 02:22 PM #32

I like :-)

But you should maybe use some beefier boost hose clamps....

This post was last modified: 01-29-2012, 02:26 PM by majesty78.

Mercedes Benz W210 E-Class 320CDI, lowered 2.5", 18" AMG wheels, Decat, EGR removed, Tumble flaps removed, C30 AMG injectors, 400kpa MAP, Custom GT2566XTV turbo, SW tweaked to 300+hp/750Nm Big Grin

majesty78

01-29-2012, 02:22 PM #32

I like :-)

But you should maybe use some beefier boost hose clamps....

Mercedes Benz W210 E-Class 320CDI, lowered 2.5", 18" AMG wheels, Decat, EGR removed, Tumble flaps removed, C30 AMG injectors, 400kpa MAP, Custom GT2566XTV turbo, SW tweaked to 300+hp/750Nm Big Grin

EDH_Performance

Holset

537

01-29-2012, 05:48 PM #33

(01-29-2012, 02:22 PM)majesty78 I like :-)

But you should maybe use some beefier boost hose clamps....

If they pop off I will Wink

Haven`t happend yet.. I have acsess to some really beefy clamps, but they are more expensive than those i have now Smile

EDH_Performance

01-29-2012, 05:48 PM #33

(01-29-2012, 02:22 PM)majesty78 I like :-)

But you should maybe use some beefier boost hose clamps....

If they pop off I will Wink

Haven`t happend yet.. I have acsess to some really beefy clamps, but they are more expensive than those i have now Smile

Booster

GT2559V

240

01-30-2012, 08:51 AM #34

Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Booster

01-30-2012, 08:51 AM #34

Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Rub87

Naturally-aspirated

21

01-30-2012, 10:45 AM #35

Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

Rub87

01-30-2012, 10:45 AM #35

Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

EDH_Performance

Holset

537

01-30-2012, 11:13 AM #36

(01-30-2012, 08:51 AM)Booster Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Hi,

I have some more photos of it, if you want to see?
But I made the collector along the way, just started with two runners and mended the others into them. And after that I welded some inside and ported the collector to a smooth finish Smile

The turbo flange made I myself, the Head flange comes from klracing.se.

The power goal is high, I have seen 614hp on stock engines(upgraded valvesprings). And as I also will fit special high duration cams and stiff springs, who knows? I WANT BIG POWER Big Grin

I will also get my hands on a BMW 330D/530D transmission, these can handle almost 1000nm (does the BMW guys say)

(01-30-2012, 10:45 AM)Rub87 Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

Haha, agree! I looks better with the headcover on Wink

No, I haven`t made the inlet in the intake for it yet! But I will do that as soon as i get the 7.5mm pump Smile

I dont want to take the intake off two times Sad

This post was last modified: 01-30-2012, 11:15 AM by EDH_Performance.

EDH_Performance

01-30-2012, 11:13 AM #36

(01-30-2012, 08:51 AM)Booster Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

I will also get my hands on a BMW 330D/530D transmission, these can handle almost 1000nm (does the BMW guys say)

(01-30-2012, 10:45 AM)Rub87 Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

Haha, agree! I looks better with the headcover on Wink

No, I haven`t made the inlet in the intake for it yet! But I will do that as soon as i get the 7.5mm pump Smile

I dont want to take the intake off two times Sad

Rub87

Naturally-aspirated

21

01-30-2012, 11:26 AM #37

Maybe one small remark about the plenum. the big planar top surface welded at the corner under 90° will be prone to crakcing because the big surface will vibrate, and then at the 90° edge the weld will start crack from the inside.. I found out the hard way.. its better to bend the 90° on the plate and then weld in a planar section, this way the weld is only loaded on tension.. or you can also weld some studs in the big flat plate to prevent it from flexing

offcourse I see you used some thick aluminum, which also helps.. I used 3mm, but was only running around 1.7 bar, static tested with 6 bar was no problem, but the pulsation inside the plenum made it fail over time

Rub87

01-30-2012, 11:26 AM #37

EDH_Performance

Holset

537

01-30-2012, 11:40 AM #38

(01-30-2012, 11:26 AM)Rub87 Maybe one small remark about the plenum. the big planar top surface welded at the corner under 90° will be prone to crakcing because the big surface will vibrate, and then at the 90° edge the weld will start crack from the inside.. I found out the hard way.. its better to bend the 90° on the plate and then weld in a planar section, this way the weld is only loaded on tension.. or you can also weld some studs in the big flat plate to prevent it from flexing

offcourse I see you used some thick aluminum, which also helps.. I used 3mm, but was only running around 1.7 bar, static tested with 6 bar was no problem, but the pulsation inside the plenum made it fail over time

I see, let`s hope it won`t crack! But it is 10mm alu, so it is pretty strong!

EDH_Performance

01-30-2012, 11:40 AM #38

(01-30-2012, 11:26 AM)Rub87 Maybe one small remark about the plenum. the big planar top surface welded at the corner under 90° will be prone to crakcing because the big surface will vibrate, and then at the 90° edge the weld will start crack from the inside.. I found out the hard way.. its better to bend the 90° on the plate and then weld in a planar section, this way the weld is only loaded on tension.. or you can also weld some studs in the big flat plate to prevent it from flexing

offcourse I see you used some thick aluminum, which also helps.. I used 3mm, but was only running around 1.7 bar, static tested with 6 bar was no problem, but the pulsation inside the plenum made it fail over time

I see, let`s hope it won`t crack! But it is 10mm alu, so it is pretty strong!

Booster

GT2559V

240

01-30-2012, 11:59 AM #39

(01-30-2012, 11:13 AM)EDH_Performance
(01-30-2012, 08:51 AM)Booster Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Hi,

I have some more photos of it, if you want to see?
But I made the collector along the way, just started with two runners and mended the others into them. And after that I welded some inside and ported the collector to a smooth finish
The turbo flange made I myself, the Head flange comes from klracing.se.

The power goal is high, I have seen 614hp on stock engines(upgraded valvesprings). And as I also will fit special high duration cams and stiff springs, who knows? I WANT BIG POWER

I will also get my hands on a BMW 330D/530D transmission, these can handle almost 1000nm (does the BMW guys say)

(01-30-2012, 10:45 AM)Rub87 Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?
Haha, agree! I looks better with the headcover on
No, I haven`t made the inlet in the intake for it yet! But I will do that as soon as i get the 7.5mm pump I dont want to take the intake off two times

Yes please I would love to see as many as possible...

cheers

Booster

01-30-2012, 11:59 AM #39

(01-30-2012, 11:13 AM)EDH_Performance
(01-30-2012, 08:51 AM)Booster Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Hi,

I have some more photos of it, if you want to see?
But I made the collector along the way, just started with two runners and mended the others into them. And after that I welded some inside and ported the collector to a smooth finish
The turbo flange made I myself, the Head flange comes from klracing.se.

The power goal is high, I have seen 614hp on stock engines(upgraded valvesprings). And as I also will fit special high duration cams and stiff springs, who knows? I WANT BIG POWER

I will also get my hands on a BMW 330D/530D transmission, these can handle almost 1000nm (does the BMW guys say)

(01-30-2012, 10:45 AM)Rub87 Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?
Haha, agree! I looks better with the headcover on
No, I haven`t made the inlet in the intake for it yet! But I will do that as soon as i get the 7.5mm pump I dont want to take the intake off two times

Yes please I would love to see as many as possible...

cheers

EDH_Performance

Holset

537

01-30-2012, 12:13 PM #40

This is current setup, with the small 5.5mm elements maxed out!

[/quote]

Yes please I would love to see as many as possible...

cheers

[/quote]

Here you go mister Wink

This post was last modified: 01-30-2012, 12:20 PM by EDH_Performance.

EDH_Performance

01-30-2012, 12:13 PM #40

This is current setup, with the small 5.5mm elements maxed out!

[/quote]

Yes please I would love to see as many as possible...

cheers

[/quote]

Here you go mister Wink

erling66

SuperDieselVan

294

01-30-2012, 01:36 PM #41

I am very impressed with your fast progress, maybe there is nothing else to do in Arendal in the winter than working? Wink

So tell us, how does the engine feel? old engine with Eaton vs new engine with Eaton vs new engine with Eaton and turbo?

erling66

01-30-2012, 01:36 PM #41

I am very impressed with your fast progress, maybe there is nothing else to do in Arendal in the winter than working? Wink
So tell us, how does the engine feel? old engine with Eaton vs new engine with Eaton vs new engine with Eaton and turbo?

Booster

GT2559V

240

01-30-2012, 03:09 PM #42

Manifold looks good, what have you done about wastegate?

Booster

01-30-2012, 03:09 PM #42

Manifold looks good, what have you done about wastegate?

EDH_Performance

Holset

537

01-31-2012, 09:27 AM #43

(01-30-2012, 01:36 PM)erling66 I am very impressed with your fast progress, maybe there is nothing else to do in Arendal in the winter than working?
So tell us, how does the engine feel? old engine with Eaton vs new engine with Eaton vs new engine with Eaton and turbo?

Old engine vs Mr. Eaton: Very good, powerful engine with N/A characteristics. No "turbo" lag....Had 0.2 bar on idle and 0.9 at around 3000 and up. It was a bit smokey (blue) on cold starts and idle. A bit ruff at idle when cold. And the engine was a bit "choky" at the top of the rpm. It is a good "cheap" way to do it...Stick a Eaton m90 or turbo, and tune the stock 5.5mm pump, and you get around 170-180hp. The car uses around 0.7ltr/10km on higway driving

New engine vs Mr. Eaton: Same as above, but no smoke at coldstarts, smooth idle. A bit more powerful on the top end (the porting helped!)

New engine vs Turbo+Mr. Eaton: Way more power on higher rpm! The intake preassure comes much faster! The exhaust sound is completly different, much better Big Grin

So i can`t wait to get my 7.5mm elements!!!!

EDH_Performance

01-31-2012, 09:27 AM #43

(01-30-2012, 01:36 PM)erling66 I am very impressed with your fast progress, maybe there is nothing else to do in Arendal in the winter than working?
So tell us, how does the engine feel? old engine with Eaton vs new engine with Eaton vs new engine with Eaton and turbo?

So i can`t wait to get my 7.5mm elements!!!!

huseyin55amg

Naturally-aspirated

20

02-08-2012, 12:04 AM #44

awesome stuff , well done ...!!

huseyin55amg

02-08-2012, 12:04 AM #44

awesome stuff , well done ...!!

SurfRodder

Jackass Extraordinaire

611

02-09-2012, 07:45 PM #45

wish I wasnt away for so long... cant see any of the pics due to bandwidth limitations. If Mr. EDH will send them to me I'll see if I can host them on my domain.

W123 Mods: 4 speed ** manual climate control ** '85 Kalitucky intake ** manual windows & full tint ** Euro headlights retrofit w/bixenon projectors ** 4 brake light mod ** Vogtland 50mm drop front & Lesjofors S600 drop rear springs ** 16" rims ** late w126 brake spindles, rotors & calipers ** full suspension rehab ** Bilstein HDs ** AL129X alternator & 1/0 starter and charging cables ** 300GD clutch/flywheel ** AFCO 80103N radiator & Earl's 41610 oil cooler ** custom block-off plate, remote oil filter & t-stat ** MW IP w/ tomnik's 6.5mm 'Holly' elements **

S124 Mods: 400E Rear subframe ** SL600 Brakes ** Late 300E 210mm diff ** SLK230 6 speed ** 17" CLK rims ** Vented RF Fender ** Facelift Hood, Headlights, and Lower Cladding **

OBK# 62

SurfRodder

02-09-2012, 07:45 PM #45

wish I wasnt away for so long... cant see any of the pics due to bandwidth limitations. If Mr. EDH will send them to me I'll see if I can host them on my domain.

EDH_Performance

Holset

537

02-10-2012, 09:42 AM #46

(02-09-2012, 07:45 PM)SurfRodder wish I wasnt away for so long... cant see any of the pics due to bandwidth limitations. If Mr. EDH will send them to me I'll see if I can host them on my domain.

It isn`t your bandwith thats wrong, it`s my photobucket account that is full, and I need to pay them more money Wink

I will fix it soon, so stay tuned Wink

Dieselmeken pump with large elements is soon on it`s way guys!

EDH_Performance

02-10-2012, 09:42 AM #46

(02-09-2012, 07:45 PM)SurfRodder wish I wasnt away for so long... cant see any of the pics due to bandwidth limitations. If Mr. EDH will send them to me I'll see if I can host them on my domain.

It isn`t your bandwith thats wrong, it`s my photobucket account that is full, and I need to pay them more money Wink

I will fix it soon, so stay tuned Wink

Dieselmeken pump with large elements is soon on it`s way guys!

EDH_Performance

Holset

537

02-13-2012, 08:10 AM #47

Took the turbo off and installed my exhaust temp sensor, just between the ports.

[Image: IMG_3859.jpg]

Eksos sonden ligger akkurat imellom begge kanalene rett før impeller.

[Image: IMG_3860.jpg]

And some fitting for 4mm coppertubes for exhaust preassure Smile

Now is everything ready for the new pump Smile

EDH_Performance

02-13-2012, 08:10 AM #47

Took the turbo off and installed my exhaust temp sensor, just between the ports.

[Image: IMG_3859.jpg]
Eksos sonden ligger akkurat imellom begge kanalene rett før impeller.

[Image: IMG_3860.jpg]
[Image: IMG_3861.jpg]
And some fitting for 4mm coppertubes for exhaust preassure Smile

Now is everything ready for the new pump Smile

dieselmeken

Holset

407

02-14-2012, 12:24 PM #48

EDH Performance pump has left the building. ( also some nice stickers will come with the receipt from Dieselmeken AB )

http://www.facebook.com/dieselmeken

dieselmeken

02-14-2012, 12:24 PM #48

EDH Performance pump has left the building. ( also some nice stickers will come with the receipt from Dieselmeken AB )

http://www.facebook.com/dieselmeken

EDH_Performance

Holset

537

02-14-2012, 04:05 PM #49

(02-14-2012, 12:24 PM)dieselmeken EDH Performance pump has left the building. ( also some nice stickers will come with the receipt from Dieselmeken AB )

I like it

EDH_Performance

02-14-2012, 04:05 PM #49

(02-14-2012, 12:24 PM)dieselmeken EDH Performance pump has left the building. ( also some nice stickers will come with the receipt from Dieselmeken AB )

I like it

EDH_Performance

Holset

537

04-09-2012, 09:41 AM #50

Since my photobucket is out of order, i can`t oppload any pictures yet.
But many things have been done Smile

A BMW E39 530D manual gearbox has been fitted, and finally the gears holds Big Grin

The turbo pressure is just 1.9bars and exhaust pressure is 1.8 bar, so still looking good! It smokes a bit still, so more boost is needed...But this is very easy to change Wink

Did some test her the othe day:

This post was last modified: 04-09-2012, 09:45 AM by EDH_Performance.

EDH_Performance

04-09-2012, 09:41 AM #50

Since my photobucket is out of order, i can`t oppload any pictures yet.
But many things have been done Smile
A BMW E39 530D manual gearbox has been fitted, and finally the gears holds Big Grin
The turbo pressure is just 1.9bars and exhaust pressure is 1.8 bar, so still looking good! It smokes a bit still, so more boost is needed...But this is very easy to change Wink

Did some test her the othe day:

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