TD04 Bolt on Kit Designing and Manufacturing

[Gly]

not mine still plan on doing the conversion at some stage...

depends how good your cast alloy welding skills are??
working with the bends as is would create some interesting pipe work

straight ones would be easier to work with,

[VR4WGN]

itll be easier once iv done it i guess,then youll know what to do then

[Turbo_Steve]

90 deg inlet on the rear one woudn't be a problem as far as I can see: would actually make the pipework simpler?

The front one would be a pain with that Rad pipe in the way...however the factory pipework pretty much comes straight out into a 90degree bend anyway?

Just a thought.


And I did say rareR not rare. There are plenty of straight entry ones around (used on UK models from 1998 - 2000) however the 90degree entry ones are even more prolific, at least in the UK.

[Gowf]

Q: I'd get them onto the standard manifolds, no messing just drill the extra hole end get them mounted and see how they sit against the engine. Then I'd get said engine into the car and see what it looks like in terms of space. That is likely to make most of your decisions for you!

Also, bear in mind that those turbos you have are available with both 90degree and straight inlets: you can clock the inlet round on a 90degree, which may make custom inlet piping easier...or harder!

The issue you may have is that if mounted to the stock manifolds in the way you've suggested there will be clearance issues with the block, something you cant just bodge out of the way.

TD05's are bigger, but they do clear oddly enough. Just a heads up. So the best solution would be to have more than just a mock engine, youd need to replecate everything in the engine bay also in terms of dimensional clearance.

[Turbo_Steve]

You're the expert here!

If TD05s DO fit and TD04s don't presumably we're talking less than 3cm difference....so for example longer studs and a steel spacer block on the manifold?

I've offered a TD04 up in mine, and it's EXTREMELY close.....

[Gowf]

I couldnt tell you the exact clearances, as ive not measured them, but obviously the td05's dont clear the bulkhead, neither do the td04's for that matter, so a wee bit of mod is required (a hammer would do for the 04's nbut cutting for the 05's i think).

Yeah they are close, but you will have issues unless like everyone else who has used stock manifolds use a spacer plate.

[VR4WGN]

hmm interesting,just the kind of discussion i was waiting for...

firther more Gowf i will be keeping a front cut from a legnum and keeping it all attached and setting it up to drop and play with the motor etc so it will be a quick test for space and fitment etc.

but definalty keep the discussions going guys,any problems are going to be good to hear and air out and sort solutions then i hope...

[taupodrifta]

have you got any further with these Q

[Louis]

I thought that valmes had fitted his tdo4's straight onto the orig manifolds, then went to tdo5's, I'm sure he didn't use a spacer on the TD04's

[VR4WGN]

buzy setting up factory so no ,not yet,i have just about evrything i need to proceed but time......

[timmae2009]

Updates ???

[kochajj]

its my td04 upgrade... no flange, ori oil/water line... no oil relokation kit...















[img=http://images42.fotosik.pl/202/76fd6dd488b15880m.jpg]

[bradc]

That looks very good as usual

[Louis]

That's looking good, well done, It looks like you have managed to get it ot fit without having to cut the front engine roll stopper engine mount??, and you have also managed it without having to relocate the oil filter??, it would be good if you have, cheers

[Gly]

got pics of the rear turbo fitment??

[Gly]

also which car is that tdo4 off? and which variation is it?

[phosty]

Looks like more than the work of a dremel hand tool:

http://www.fotosik.pl/pokaz_obrazek/...14817704d.html

Very nice!

[kochajj]

rear turbo is not finisch. turbo is from subaru (td04l-13t)...

http://www.fotosik.pl/pokaz_obrazek/...63db594f9.html
http://www.fotosik.pl/pokaz_obrazek/...235abbb0b.html

[dinger1983]

to get that milled is not gona be anywere near as expensive at custom manifolds of even custom pipe work id the standard stuff fits back on

in fact i may have to get some spare manifolds and my mate spare turbo and ask one of the mettal bashers in the work to mock it up wile im still in the raf and have access to them cos this looks like the way forward

[Turbo_Steve]

It looks great, and if it works it's a real win!

My only word of caution would be around EGTs removing that much metal from the manifolds - they're big for a reason! No sure what it's going to look like inside after the milling, but a hot spot is going to result in cracking.


That said - they're cast so will take a LOT of heat.

Thank you for sharing - VERY interesting stuff.

Any plans to sell it as a kit?