The chra of my new k04 is done  









It's a 50/44.5mm turbine with 2280 compressor, new bearings, seals etc and balanced. Now the next step is to machine the housings  
I sold the 370cc injectors already, going for 550cc because they work awesome on my other project as well.

It's that time of the year, a dream came true for me  





Just need to find another bottle of Argon to get this thing running, first project: tubular manifold  

At this moment I'm still on stock AEB injectors @ 4.5 bar. I never really drive on petrol though, just starting and maybe the first km when its cold. They are just about maxed out even on the small K03... I plan on using Bosch/Ford 550cc's when upgrading the turbo, I have put these in another car I've other built and they work very well. For my car I need to shorten the fuel rail height though, or shave the manifold or add spacers. Downside of an AEB intake manifold. I plan on adjusting the fuel rail brackets, I think that is the cleanest option. *and then I found these 550's in a 10mm longer body  problem solved.
Heres a picture of the short 550cc's:

Done some good deals the past weeks, I sold both the ECU and the turbo of the spare engine, earning back the €450,- plus I sold the injectors for €75 so I am now actually making money on my spare  
Picking up the engine in my bus:


It's laying massively in the way (I have a really small workshed and it is literally laying in the doorway so I have to step over it to enter ) so I decided to practice my tig welding by making an engine stand. Just need to pick up some tubes for the turnable mount.


I also got started on collecting parts for my new manifold! Just need to make some mockup bracket on my engine so I can weld it and testfit on the spare block so it will roughly match my downpipe.


And I welded a 3" stainless TIP for our project Audi TT to match the turbo inlet. Just need to wait for the silicone hoses, its a 90degree 76mm from the tip to the turbo and a 45 degree 76mm to 80mm from the tip to the MAF.


I also bought a B7 A4 ecu (518AQ) to experiment with, turns out there is hardly any definition files for it but I can always crossflash it with the 518AK.. I started disassembling it to try to locate more maps but as always process is slow. I guess I am spoiled with my 512kb fully defined file, so much easier to do specific modifications... Might pick up another wideband ecu (but then go for 05.12 bootrom type) when I get to sell this A4 ecu for a decent price.
And I finally ordered my new injectors, the long Bosch 550cc's. Expecting them next week  

Clutch is in for a couple of weeks now, slight issue with the pressure plate that grinds on something during starting starter motor that is on its way out and offcourse a dead throw out bearing that I did not replace
Will have to pull the gearbox again eventually, but for now its fine.


New and old side by side


I bought a big Makita disk cutter second hand for just 25€ and after fitting a new disk I was ready to try my first collector for the k04 manifold.
Only problem is I bought galvanized tube, so welding kind of sucks. But I managed to get it clean enough for good result:


Welded inside and outside for maximum welding credit   (or to cover up imperfect fitment...)


And there she is on the turbo. Have to think about studs/hex/allen bolts and fitment because this pipe is on the edge of too large for a k04 flange   still able to tighten the allen bolts at this time, so hope it will be ok. Probably need to go for I just found a bag of M10 SW14 nuts in my shed that will fit with the M10 studs  


Inside comparison with k03mani


Positioning hotside on spare block


So thats it for now, will post a log soon to show how the bus is running on the wideband setup

Machining the turbo today

Needs a little trimming of the curved section between inducer and exducer, because of larger tip height. Did not manage to finish it today unfortunately.
Exducer sizing is good, so thats nice.




So, on to the manifold. Cylinder 1 is done, so next up was cylinder 2 and 3. Looks good to me


This was during test fitting, not everything aligned. Its all in the right place now. I really like how equal the header lengths turned out so far!


And some days ago my other AEB head came by mail, I just gave it a quick wash and will be dismantling it soon. I will fit uprated exhaust valves to it and thats about it. It will go onto the new engine that I currently use for building the manifold, so when I get to swap engines I dont have to worry about different size ports. Besides, why would I downgrade my upgraded engine with a small port head  


Just got back from the shed, I finished the initial fitment of the tacked manifold *happy* 

Today back to the workshop, tied the compressor housing to the lathe and gave it a whirl


After some measuring and removing the housing and then concluding that the compressor wheel still makes contact, I managed to get it to fit 


Tadahhh

Ah yes, sorry mister Terror Flynn, I found out it was actually a 150hp file. But don't worry, follow my link to the full definition and make it better than 180hp yourself! 
http://nefariousmotorsports.com/forum/index.php?topic=10354.msg90466#msg90466