Custom intake manifold *PICS*...etc

[Pagz]

Heres a few pics for all that have been following the build...truely a sight for saw eyes given the trouble in the last 12 months!

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_267_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_265_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_264_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_266_full.jpg



Here you can see the beautiful bell mouths used inside the plenum...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_268_full.jpg



Heres a few pics of the car since its been so long now...
i like the rear wheels but the fronts are another story,hopfully the stoptech kit will make it look alittle better in that area.
the car is also sitting alittle high given its missing the exhaust,turbo and all liquids...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_270_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_274_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_275_full.jpg



The turbo is again a top mount to give a nice 4-1 and still have room for the wastegate with plenty of engine movment clearance...we did shift it further back and down after i took this pic...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_273_full.jpg


There is still alot to do in the bay,the new cam cover should be complete this week,and where looking into washer/cam breather combo for the left side,and maybe even a matching coolant tank for the right,as well as the IC piping and intake...
Thanks all,
Paul

[matt09]

Just look at that turbo.....
BTW, I am very ignorant when it comes to engine internals, but shouldnt the manifold have some kind of pattern inside it so it sends air more efficiently to each cylinder? Arent you going to get more pressure on the last one compared to the first?

[omeyhomey]

is it normal if i get turned on by an intake manifold :D ;) . WOW fantastic work... I love it keep up the great work.

[Proven Guilty]

Originally posted by omeyhomey
is it normal if i get turned on by an intake manifold :D ;) . WOW fantastic work... I love it keep up the great work.

TOOK THE WORDS RIGHT OUT OF MY MOUTH BROTHA!

paul, i would sell my firsbtorn child to buy this car from you when it's complete.

loooool at the power steering fluid resevoir under the intake. you built the coolant expansion tank from scratch, any plans for that? i can't believe what a beutiful mirror finish they polished out the intake to be. i'm in total shock.

[Markland556]

simply one of the best C class's out there.. What kind of front bumper is that?

[Pagz]

Omey,PG,
hahaha...must say it was instant creamage when i finally laid hands on her this avo!!!:D


LOL @ selling your kids:D

haha that damn power steering resevoir!!!sooo always in the way!!...and sooo hard to shift lol...got the ":Paranoid:" look when i told him to put the TB there...could you imagine how it would have looked if the TB sat to the right of it?...i couldnt so that was that;)...

still trying to decide if we anodiz all the polished parts in a clear finish,or maybe a clear coat...but yeh the polish finish he did is excellent!
as for the custom coolant tank,there is a high chance it will be swapped out for a nice "radiused egde" item...however i may attempt to remove the float switch system from the first unit to install in the new...will see when the bill comes through and if i will have anything left to live on lol


Thanks markland,thats a "Lumma tuning" bumper,made in germany.

[Luwin1026]

Looks oh so hot . . . gonna get a rear kit to finish her off?

[DRM]

looks insane! nice work

[Ashkan's C280]

wow great work mate

[Pagz]

Luwin,DRM,Ashkan,
Thanks guys!..
Im not to keen on most rear bumpers for the 202,im happy with the updated one for the time being...but things are always changing;)

[RacerXofFL]

Originally posted by omeyhomey
is it normal if i get turned on by an intake manifold :D ;) . WOW fantastic work... I love it keep up the great work.

aheam, this should be tagged NSFW

[RemoLexi]

Thats hot! I know Local CHP would give me the death sentence if I get caught with something like that under the hood of my car :(

M111 never looked this good! although one thing that im surprised about is not seeing a gigantic chrome radiator to keep the cool ? ... your going to need it I know that since W202's already run higher temps then the other cars out there ... and im already looking into a radiator and a small seperate oil cooler.

[RemoLexi]

and I really dont know about those rims, Milano's looked so clean and neat ... these look like they belong on a 240SX or a Silvia.

[Pagz]

Originally posted by matt09
Just look at that turbo.....
BTW, I am very ignorant when it comes to engine internals, but shouldnt the manifold have some kind of pattern inside it so it sends air more efficiently to each cylinder? Arent you going to get more pressure on the last one compared to the first?

Hi,
It depends alot on plenum size and plenum intake angle from what i gather,it is unlikely there would be more pressure at the far end,but if the plenum was to small you could expect other cylinders to starve nieghbouring ones thus causing pressure difference...

while on the tech descussion....im suprised PG didnt question the short runners:D...which wasn't calculated to suit any specific torque range...but i know it will better the top end at the cost of low...will be interesting to see just how much though!

[RacerXofFL]

do master craftsmen work for like 5$/hr there? you must be like 20K into this motor....

[Pagz]

Remolexi,
Yer the rims are a love hate thing,they werent quite what i had planned,but there growing on me slowly;)

As for the radiator,cooling doesnt seem that bad at all,the only time i heard the alarm go on the defi gauge was when i had just taken it for a rip round the block and it was sitting at idle for ~3 mins without the viscous fan installed!!!.
also our temps down here are usually between 10 - 25 degrees C all year round.

RacerXofFL,
NSFW??
and Aheam = omey?

thanks,
Paul

[RacerXofFL]

Originally posted by 23K
RacerXofFL,
NSFW??
and Aheam = omey?


Not Suitable For Work : how we label porn and whatnot...


Now how bout the money aspect, would you like to be hosted on turbobenz.com?

[Pagz]

Originally posted by RacerXofFL
do master craftsmen work for like 5$/hr there? you must be like 20K into this motor....

lol i wish...usually $60-65NZD +12.5% GST

[Pagz]

Originally posted by RacerXofFL
Not Suitable For Work : how we label porn and whatnot...


Now how bout the money aspect, would you like to be hosted on turbobenz.com?

Ahh yip;)

havent got any plans to have it hosted yet,will let you know if or when i do!

[RacerXofFL]

Originally posted by 23K
lol i wish...usually $60-65NZD +12.5% GST

so u have had 3-4 tb mani's made, the intake, the built motor (2 sets of bad pistons ((added build time)) etc etc) between the bodykit, 2 sets of rims, and engine you have spent well over 20K and you have stoptechs on the way? (+4K more...)

[RacerXofFL]

Originally posted by 23K
Ahh yip;)

havent got any plans to have it hosted yet,will let you know if or when i do!

I own turbobenz.com, Im offering to host it for you for free, your car is insaine...

[RemoLexi]

cmon .... big huge radiator .... come on more chrome!!

you know you want one now and I know your gonna get one!

:bunny:

[RemoLexi]

Originally posted by RacerXofFL
so u have had 3-4 tb mani's made, the intake, the built motor (2 sets of bad pistons ((added build time)) etc etc) between the bodykit, 2 sets of rims, and engine you have spent well over 20K and you have stoptechs on the way? (+4K more...)

just look at his name - 23K means 23K he spent extra to make his 23T! :p

[Proven Guilty]

Originally posted by 23K
Hi,
It depends alot on plenum size and plenum intake angle from what i gather,it is unlikely there would be more pressure at the far end,but if the plenum was to small you could expect other cylinders to starve nieghbouring ones thus causing pressure difference...

while on the tech descussion....im suprised PG didnt question the short runners:D...which wasn't calculated to suit any specific torque range...but i know it will better the top end at the cost of low...will be interesting to see just how much though!

Haha :D I honestly didn't question it, because my assumption was right on track with your explained reasoning above. I agree with the given pics, that the preassure of the air and given clearances due to plenum size/angle, this should work PERFECTLY.

Luckily you've got stand alone, and that really nice digital read of A-2-F to keep a close eye on the trial run in the event that its not the case!

As far as the looks, I like the SUBTLE anodized parts you have now, coupled with the blue silicon tubes etc, and I think with the Silver painted Kompressor spark plug cover it sets everything off great. I wouldn't touch anything, because it looks AMAZING as it is with a high lustre polish. If you were to clear blue anodize anything else, it would start to take your eyes away from the real prize and craftsmanship.

The rims - they are starting to grow on me as well. I'm a huge fan of the Milanos / Carlsson 2/5s look, but I love me some 3-piece wheels too! I'm hooked on the milanos simply because they took the effort to make a quality looking fake 3-piece wheel, as it's a 1-piece construction with rivets added. That Lumma bumper REALLY grew on me now that you have the C36 sides. I think the WALD rear bumper would set your car on FIRE! and remove/reinstall the chrome strips to black out the stock grille. It's amazing what a difference it makes when that sun-faded washed-out gray stock grille gets a nice coat of black enamel laid over it, and new chrome strips installed. trust me on this one!

[Pagz]

RacerXofFL
Thanks,ill PM you when i get things running!
the project has cost alittle more than i was willing to spend...i dont really know how much now,i know alot has been wasted!.

[Pagz]

PG,
haha...Yer,i guess you need only compare to other high performance manifolds made for GTR's,silvia's etc to know this compact design works very well!

If i have the plenum anodized it will be a clear anodize,a bit like the TB is now but maybe not so dull...otherwise i will keep the polished look...also the new cam cover is powder coated in a charcoal colour...which i was very limited in colour to for some reason...wont know if it looks good until i try it on!

funny you should mention the wald rear....if any,that would be the one i would get!...and as for the grill im definalty thinking of changing to a black finish!...we will see;)

[RemoLexi]

Paul, I think ive sent you a PM regarding this but im not sure what happen to that, anyway,

how do I get the oil feed into the turbo, Ive seen the thread showing how to have the oil return line into the sump, but wheres the feed out of what do I need to buy and how do I wire that up ?

same question goes for the waterfeed/return line ?

Please help as this is my next step and I need to learn this stuff quick as my turbo should show up sometime this week and Monday at most.


EDIT: also very curious about the Oil temp./pressure guages those are a must and I may as well get those in this step as well to get it over with!

Thanks!

[Pagz]

Originally posted by RemoLexi
just look at his name - 23K means 23K he spent extra to make his 23T! :p

haha yeh,OK...well i guess your not too far of the truth:)

[Pagz]

Originally posted by RemoLexi
Paul, I think ive sent you a PM regarding this but im not sure what happen to that, anyway,

how do I get the oil feed into the turbo, Ive seen the thread showing how to have the oil return line into the sump, but wheres the feed out of what do I need to buy and how do I wire that up ?

same question goes for the waterfeed/return line ?

Please help as this is my next step and I need to learn this stuff quick as my turbo should show up sometime this week and Monday at most.


EDIT: also very curious about the Oil temp./pressure guages those are a must and I may as well get those in this step as well to get it over with!

Thanks!

Thats weird...i did a full reply and links to other threads...lol took ages...


oil feed is located about half way down the dipstick on the block,its a 6mm hex key bung.

As for the water feed there is possibly two ways to do it...i think the better is from the block coolant drain(located under the exhaust manifold),and return from the turbo to as close to the pump as possible ...
http://www.club202.com/forums/showthread.php?s=&threadid=8696&highlight=water+feed

[RemoLexi]

ok yea I figure the water feed/release wasnt too complicated, now as the oil feed line ill look at my car first before i reply to anything.

ok, now the oil feed line I see has two sensors inturupting it ... the oil pressure senser and the temp. sensor which then send info to the gauges correct ? so that billet block you have bolted to the front of the engine just holds those two sensers ?

[Pagz]

Just remember the coolant pump doesnt pump water under pressure...it simply circulates the coolant,thus the importants to make a low restriction parallel path for the turbo water jacket.

I brought the feed from the hex key bung i mentioned up to the twin sensor block on the front of the head then over to the turbo where it goes through a 1mm restrictor inside the banjo bolt i used.

[RemoLexi]

ahha ! ok, yea like an hour ago I was stressing out "like what is that shiny thing" and now im finally learning this thanks to you!

Im thinking of tapping the top ortion of the thermostat housing and around to the turbo .. yes / no ?

then the coolent outlet line go directly into the plastic tank ?

[RemoLexi]

and the oil inlet - the hex key bung your talking about does that have some pressure enough to circulate the oil to the turbo ?

... sorry if im bugging you with all my questions and all, just this is the easiest way I can get answers from.

[Pagz]

http://www.club202.com/forums/showthread.php?s=&threadid=8696&highlight=water+feed

cruise over to this thread man...ceo there:)

[Pagz]

Originally posted by RemoLexi
and the oil inlet - the hex key bung your talking about does that have some pressure enough to circulate the oil to the turbo ?

... sorry if im bugging you with all my questions and all, just this is the easiest way I can get answers from.

Yes there will be plenty of oil pressure,unlike the cooling system the oil pump out flows the path oil takes inside the engine by alot,thus causing a decent pressure difference between the pump and sump.

[SLAMMED_C]

PAUL!!!.. oh my! that looks sweet indeed.
I love that intake manifold!.. I WANT ONE!!
car is coming along nice now.. is the turbo header actually in there or is the turbo just sitting there for the pics?
Car is nice man.. cant wait to see her finished off.
any estimate of when the engine will fire up and run.. dont forget to get vid of the first fire up.. and of the first roadtest!
gotta see and hear this beast in action.
Im sure the BBK will help with the look of the fornt wheel.. what colour are the calipers going to be?
car is amazing mang. nice work.. its taken a while to get this far.. but with all teh troubles you have had on the wway.. its finally getting near the home stretch.. and i must say its going to be one hell of a car.
keep up the great work Paul.

[Pagz]

Thanks dude!,the turbo was just sitting in there that day,we did shift it closer to the engine,alittle further down and back....even though i really wanted the compressor housing back behind the cam cover recess,I had to agree it made things too tight!...so again its a fairly high top mount setup...this time much better made!...
Hard to say...it should be another 8-12 weeks,but lack of spare cash might drag it alittle longer...but when i do there will definatly be some footage;)...
calipers are in...you wouldnt have guessed it...SILVER..lol
thanks again dude...laters!


Originally posted by SLAMMED_C
PAUL!!!.. oh my! that looks sweet indeed.
I love that intake manifold!.. I WANT ONE!!
car is coming along nice now.. is the turbo header actually in there or is the turbo just sitting there for the pics?
Car is nice man.. cant wait to see her finished off.
any estimate of when the engine will fire up and run.. dont forget to get vid of the first fire up.. and of the first roadtest!
gotta see and hear this beast in action.
Im sure the BBK will help with the look of the fornt wheel.. what colour are the calipers going to be?
car is amazing mang. nice work.. its taken a while to get this far.. but with all teh troubles you have had on the wway.. its finally getting near the home stretch.. and i must say its going to be one hell of a car.
keep up the great work Paul.

[spm 16v benz]

I can't wait to see you finish this car 23K, i can't imagine how you feel. Actually no wait I can, my car I haven't been able to dive it for 2 yrs but thats what I get for buying it broken. But I got it for about 1/4 of the price of a running one.

Loving that manifold dude.......its so sexy, good luck wit future mods hopefully not to many more to get it running.

[Pagz]

2 years!,you must be past dying to get it going!:D
with those pistons is should definatly be worth the wait!
Thanks,i hope it doesnt take tooo much longer!,theres still a bit to do!;)

[RemoLexi]

Now I bet your tired of answering all my questions, but in your other thread showing the intake manifold flange I see alot of grooves for the gasket ... are they all really that neccesary ?

also are you using a custom fuel pressure regulater ? I dont see one on your fual rail.

[Pagz]

The OEM gaskets do not need to be machined in to the flange...however you would need to have a gasket made to suit the head/flange...
the flange would still need the grooves between ports for crank venting and the gasket would need provision for this also.

Yip i have a SARD 1:1 rising rate fuel regulator,it will be positioned under the manifold.

Paul

[RemoLexi]

yea Im planning to buy an OBX racing FPR, but how do I know what rate i should use/pressure ? and disconecting my stock FPR is just taking out that vacuum tube and putting that tube to the new FPR right ?

[Pagz]

The aftermarket FRP will serve two perposes...you will be able to adjust the fuel pressure...which in most cases is between 40-80psi...i think my idle pressure in the 230K was about 48.
the second perpose is to raise pressure as boost increases,because if you didnt raise it than actual fuel pressure at the injector jet would drop...so a 1:1 rate will raise fuel pressure at the same rate boost increases.

I removed my OEM FRP(custom bung),it just becomes a restriction in the system...however i did run into problems with the new regulator...even at the same pressure as stock i got pinging in the lines,im not sure if this will be common,but will find out alittle more when its all going again.

[RemoLexi]

A 1:1 rate how do I understand that ?

and whats pinging in the lines ?

[Pagz]

Heres the FRP i have used,its a SARD unit with an adjustable range of between 200-800KPa.
fuel is feed to the rail/injectors,then to the side of the regulator,through the spring loaded diapham and out the bottom which returns to the tank...
The small fitting on top is where pressure from the plenum is fed,this gives the FRP a pressure reference,when pressure in the plenum rises...ie under boost,...the FRP receives the same pressure against its diaphram which increase fuel pressure at a 1:1 ratio...ie 1 psi of boost will increase fuel pressure by 1psi...

think of the pressure inside the intake plenum runners pushing back on the fuel in the injector...if you didnt compensate for this then boost pressure would lower the potential fuel pressure as boost rises.

You will need to adjust pressure to the optimum setting on a dyno when tuning the new turbo setup...

The pinging in the lines is most likely fluctuation of sorts...either caused by the opening and closeing of the injectors or maybe the pump,my system may require i dampener at one end of the rail...i will look into it alot more when it running again.

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_288_full.jpg

[Pagz]

also after thinking alittle more...Yes you will need to modifiy or remove the OEM regulator...otherwise you will have two in series...i remember i cut the bottom off mine so that fuel bypassed it...i then decided to replace it with a bung because i thought the diaphram may have been causing the pinging...which seemed to work for all of 5 mins until it started again...so it got me baffled for now...anyways heres the bung i had made...i could give it to you if you ever end up needing it...or you could have one made by an engineering shop...or if you have a nice lathe with the right cutting tools;)

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_289_full.jpg

[RemoLexi]

yea I guess ill hold that off til Dyno time!

yea man I was thinking of a FPR plug like that but I guess your way ahead of me.

If your not going to be needing that Plug ill take it off you, email me your paypal Email and ill pay the shipping.

heres what ill be ordering soon, what do you think ??

http://www.motorenergy.com/images/obx_fuel_regulator_10741_silver_me.jpg

So tomarrow the turbo should be here, im dieing for it and I need to start bolting things together - like the manifold to the turbo and the hotside alltogether for good! ... im considering removing the compressor wheel housing and having it polished to chrome look, still debating.

[RemoLexi]

... i still dont understand "pinging", like is that when the lines get over boosted or ? cant you get steal-braided ?

I swear if i see another blue fitting ill puke - LMAO man you have them EVERYWHERE! :p

so the vacuum line that goes to the FPR is from the intake manifold ?

[Pagz]

By using the term "pinging" im refering to the noise that can be heard...why the noise can be heard may be because of fluctuation...

Imagine every time the injector opens...fuel flows,pressure drops suddenly....injector closes,pressure rises suddenly...you FRP should absorb these fluctuations in pressure assuming the pump isnt causing some of the problem...
but because im not 100% sure this is the cause,i will need to wait until i have it all running again!

haha Yer they seem to only make the ones i want in blue!...i did get the -10's for the valve cover in black though;)

Yip the FRP pressure feed has to be taken from the intake plenum.

I will get a shipping quote for you later this week..its a public holiday today!.

Iv heard ugly things about the lifespan on some regulators,as long as you have seen good reviews and have a warrenty with it there shouldnt be to much issue.

I would get the system up and running before doing any finishing touches like polishing...you will be suprised how much more work you will need to do before it goes!;)

[RemoLexi]

yea I gotcha, oh ya no rush on the stock FPR plug, i mean I wont be installing this until I have all the parts I need anyway! thanks man!

good news for me, I just found a set of guages I need including the sensers (externally mounted so no fancy customs like you) for only $150!!

[Pagz]

Sounds good!,
oh and im not too sure about that OBX FRP...i think its made to bolt onto honda fuel rails...the inlet must be under the mounting braket!(with no thread for fittings)

[RemoLexi]

can it still be used ? like depending where I mount it ?

[SLAMMED_C]

Originally posted by 23K
Thanks dude!,the turbo was just sitting in there that day,we did shift it closer to the engine,alittle further down and back....even though i really wanted the compressor housing back behind the cam cover recess,I had to agree it made things too tight!...so again its a fairly high top mount setup...this time much better made!...
Hard to say...it should be another 8-12 weeks,but lack of spare cash might drag it alittle longer...but when i do there will definatly be some footage;)...
calipers are in...you wouldnt have guessed it...SILVER..lol
thanks again dude...laters!
I didnt think the turbo header was done.. or we would have seen pics of it!!.. but it looks good sitting there.
just as long as the turbo fits in there I dont think its gonna matter if its top mount or not!! just as long as it spins!!
man thats a while to go there.. hop eit speends up.. come on Paul.. win the lottery!
cant wait for the footage.. its gonna be a beast!!
nice.. post up pics of the Stoptech kit mang.. gotta see. awww.. silver.. need to be red!! brakes that big gotta stand out!

[Pagz]

Originally posted by RemoLexi
can it still be used ? like depending where I mount it ?

I would say its likley it can still be used however you may need to make a sealed flange that will bolt up to the underside of the FRP,maybe contact the seller regarding application?

[Pagz]

Originally posted by SLAMMED_C
I didnt think the turbo header was done.. or we would have seen pics of it!!.. but it looks good sitting there.
just as long as the turbo fits in there I dont think its gonna matter if its top mount or not!! just as long as it spins!!
man thats a while to go there.. hop eit speends up.. come on Paul.. win the lottery!
cant wait for the footage.. its gonna be a beast!!
nice.. post up pics of the Stoptech kit mang.. gotta see. awww.. silver.. need to be red!! brakes that big gotta stand out!

haha the guys at work wanted them to be blue lol...im just too fond of silver;)...
heard today that the turbo manifold is done,but we just need to sort out the wastegate..so im heading over there tommorrow to sort it out...
you wouldnt believe the hassels im having with the new IC piping...my IC is 60mm,so i need a 60OD with a 56ID...but no one in the whole world has this sh!t...well,yes they do,but they would only sell me 250Kg's of it!!!.....i also need 72OD with 68ID which isnt avaliable...soooo heres the fix,tonight i got some 63.5 with a 6.35 wall...the engineers are going to machine the pipe down to 60 with a 2mm wall,so i can cut it up and make nice staggered bends with it...like how i did the intake last time...so most of the new pipes will be staggered...looks pretty trick,and is the right sized pipe!!!...it also means they can machine the raised bit that locks the pipe joiners together.
LOL man i havent checked this weeks ticket yet either:D

[RemoLexi]

Originally posted by 23K
I would say its likley it can still be used however you may need to make a sealed flange that will bolt up to the underside of the FRP,maybe contact the seller regarding application?

oh but ill be adding some aftermarket fuel lines and switching things around a bit, so I know I can most definatly have this mounted and connected then.

[SLAMMED_C]

Originally posted by 23K
haha the guys at work wanted them to be blue lol...im just too fond of silver;)...
heard today that the turbo manifold is done,but we just need to sort out the wastegate..so im heading over there tommorrow to sort it out...
you wouldnt believe the hassels im having with the new IC piping...my IC is 60mm,so i need a 60OD with a 56ID...but no one in the whole world has this sh!t...well,yes they do,but they would only sell me 250Kg's of it!!!.....i also need 72OD with 68ID which isnt avaliable...soooo heres the fix,tonight i got some 63.5 with a 6.35 wall...the engineers are going to machine the pipe down to 60 with a 2mm wall,so i can cut it up and make nice staggered bends with it...like how i did the intake last time...so most of the new pipes will be staggered...looks pretty trick,and is the right sized pipe!!!...it also means they can machine the raised bit that locks the pipe joiners together.
LOL man i havent checked this weeks ticket yet either:D
well you have to get what you want!! so silver brakes it is! I want mine to pop.. so red they will be!
woot woot!!.. get pics of that turbo manifold!!! gotta see!!
fuk!!.. thats a lot of tube.. 250kg of aluminium intake tube!!.. thats gotta be a fuk of a lot!
well you could open your own business and sell it.. ?
"Pauls intake pipe R us"!
thats awesome you will have it machined.. will be alot of work to machine it all wont it? but at least you know it will be quality.. plus the machined raise piece to lock them together is for extra security.. and all that BOOST!!
well get checkin them tickets.. you could be a millionaire!!.. dont forget to buy me a CLS55!!

[Pagz]

Originally posted by SLAMMED_C
well you have to get what you want!! so silver brakes it is! I want mine to pop.. so red they will be!
woot woot!!.. get pics of that turbo manifold!!! gotta see!!
fuk!!.. thats a lot of tube.. 250kg of aluminium intake tube!!.. thats gotta be a fuk of a lot!
well you could open your own business and sell it.. ?
"Pauls intake pipe R us"!
thats awesome you will have it machined.. will be alot of work to machine it all wont it? but at least you know it will be quality.. plus the machined raise piece to lock them together is for extra security.. and all that BOOST!!
well get checkin them tickets.. you could be a millionaire!!.. dont forget to buy me a CLS55!!

Exhaust manifold pics to come!;),its much better than the the last in terms of design and strength!...not as nice a finish as the SS because we went with cast bends...but they still did a fantastic job!.
haha Yeh tell me bout it,i was like...."I only need 500mm!",they didnt buy it
Iv added you to my "when im rich..." list :D

[SLAMMED_C]

Originally posted by 23K
Exhaust manifold pics to come!;),its much better than the the last in terms of design and strength!...not as nice a finish as the SS because we went with cast bends...but they still did a fantastic job!.
haha Yeh tell me bout it,i was like...."I only need 500mm!",they didnt buy it
Iv added you to my "when im rich..." list :D
cant wait to see the pics of the mnifold dude!.. should be good. well as long as it gets the job done it doesnt really matter how pretty it looks.. its usually the crude rude looking ones that work the best!!
lol.. nice.. just make sure its a black on black CLS55!! or Ill never talk to you again!! lol. if only we were all wealthy.. life would be so much easier!

[Pagz]

LOL,black on black.........SILVER!!!!!:D:D...jks blacks nice!,i get sh!t at work from the BWM guy ever since i showed him the family pic of the three silver benz's.
life would be soo much easier!!!...im broke 24/7/365/23... so far,man with most toy win syndrome!...this weekend we hope to get another home,looks like huge morgage though so if we can get a long settlement date that should buy me time to get the car running before im owned by the bank again,anyways enuf me blabing heres a few new pics...the car is back at my place now because where waiting on the mufflers and a few other bits...then ill ship it back to the fabricators to have the exhaust,down pipe,coolant tank,intake box,washer tank and crank vent done...in the mean time ill get the throttle cable,IC piping in and all the vaccum pips that need to come for the plenum...should keep me busy for a week or two:)

this manifold WILL do the job this time!
http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_290_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_291_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_293_full.jpg


and a close up of the fuel rail area..
http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_292_full.jpg

laters,
Paul

[SLAMMED_C]

yeh you do have a lot of silver cars at the house!!.. silver is nice.. but black is best!
lol.. well stop spending on the car and you wouldnt be broke!!
well I hope you do find a house.. you been looking alot lately?I hope you finally get one.. beats renting.

wow.. I still love that intake manifold!!.. would look so nice on my engine too!! WINK WINK!!!
whats with the blue tube inbetween the runners?.. just for looks or is it actually there to hold the 2 halves together? wouldnt aluminium pipe be better for flow?

exhaust manifold turned out really nice.. not too flash.. but still a nice piece of kit. you doing any finish to it.. coating it? looks like that shop odes nice welds too.

love colour on your valve cover.. not a silver.. but more of a gun metalish.. looks hot man.

sounds like you got lots to do still.. lots to keep you busy!

[Pagz]

silver is nice.. but black is best!
:rolleyes: :D:D:D


lol.. well stop spending on the car and you wouldnt be broke!!
LOL...man i wish,i needa get this over with.


wow.. I still love that intake manifold!!.. would look so nice on my engine too!! WINK WINK!!!whats with the blue tube inbetween the runners?.. just for looks or is it actually there to hold the 2 halves together? wouldnt aluminium pipe be better for flow?



hahaha with my luck the engine will blow,and ill make sure i remove the manifold just for you...before i push the rest of a cliff;)
The silicone couplers are there to provide heat insulation between the head and plenum,it also provides slight flexibility between the flangew/plenum and the plenum can be removed without removing the fuel system!,the pipes inside are around 1mm apart so theres no real interuption in airflow...plus i think they look good...

As for the exhaust manifold,yeh its by no means the coolest looking...but it does have the features i wanted which where strength,clearance and looks like we got away with decent flow as well;)
It will be blasted and ceramic coated black...once installed it can hardly be seen!

thanks, its done in antique steel...the camera does wierd things to the colour...even though i have the white balance set right!!,its a gunmetal colour but when the light shines on it has silver fleck so looks quite cool in the flesh...

laters mang
Paul

[Markland556]

Hey 23k, do you have a pic of your header. I would love to see a pic of it!

[Pagz]

Hey,
theres a pic on the next page back!,it still needs to be ceramic coated though;)

[Proven Guilty]

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_292_full.jpg

so clean you can see yourself in it! :D

[Pagz]

LOOOOL DAMN it had to be you that noticed:D

[RemoLexi]

23K what kind of fuel injecters are those ? mine look very differnt.

[Markland556]

I was actually talking about your exhaust header. I would just really like to see how you set yours up.

[Pagz]

Heres the pics on the next page back;)
not as flash looking as the last SS item,but far more practical.

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_291_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_293_full.jpg

for comparison heres the old one...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_142_full.jpg

[Pagz]

Originally posted by RemoLexi
23K what kind of fuel injecters are those ? mine look very differnt.

there a Siemens 550cc,they may look alittle different given the plugs are on but theres no wires yet;)

[c280nz]

Progress is looking good paul!
last time i saw a intake plenum that big and shiny it was on a drag car ;) is there something your not telling us about your intentions after the build! haha
and with 550cc injectors you could run 2 engines with that sorta capacity

[RemoLexi]

Hmm ... how do i know how many cc's my injecters are, all i know is they are 24LB / HR.

any conversion method ?

[Pagz]

Originally posted by c280nz
Progress is looking good paul!
last time i saw a intake plenum that big and shiny it was on a drag car ;) is there something your not telling us about your intentions after the build! haha
and with 550cc injectors you could run 2 engines with that sorta capacity

Haha thanks Logan im hoping it will one day perform like two engines!!... and i will have to get at least 1 run down the strip for fun;)

The magnaflow mufflers turned up out of the blue yesturday,which is all good...though as usual its never that sweet...the tips look the same as each other in the pic,but there totally different...so it'll be a few weeks before the get me another matching one...and im not to sure if ill be using them just yet..there alittle bigger than i expected.

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_295_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_296_full.jpg

So will hopfully get back in the workshop next week and get the exhaust/down pipe done...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_294_full.jpg

laters man.

[Pagz]

Originally posted by RemoLexi
Hmm ... how do i know how many cc's my injecters are, all i know is they are 24LB / HR.

any conversion method ?

hmm yeh thats a tricky one given one is measuring volume flowed per minute while the other is in wieght per hour;)...

My book says CC = Lbs/hour x 10.5

So my 550cc injector is = 52Lbs/hour.

also i read as a very general rule,5cc usually gets you around 1 HP...which would make this set of injectors good for around 440HP

this also makes your 24Lbs injectors good for just over 200HP,which is about what the stock C230K items will flow(as i had the stock items flow tested once)

however you can make injectors flow alittle more than that if your fuel system will support the increased pressure...that im really unsure about;)

[Markland556]

Hey, just wondering where you tapped your oil feed line from and where do the 2 top vents on your valve cover go to?

[Pagz]

Originally posted by Markland556
Hey, just wondering where you tapped your oil feed line from and where do the 2 top vents on your valve cover go to?

Oil is taken from a bung (6mm hex key) about half way down the dipstick on the block.

the vents arnt complete,they will vent into a catch tank to the left of the bay...it will be completed when we get it back to the fabricators=)

[spm 16v benz]

Hey 23K,

Looks like you are all most finished. Can't wait to see the dyno figure.

[SLAMMED_C]

Originally posted by 23K
:rolleyes: :D:D:D
LOL...man i wish,i needa get this over with.
hahaha with my luck the engine will blow,and ill make sure i remove the manifold just for you...before i push the rest of a cliff;)
The silicone couplers are there to provide heat insulation between the head and plenum,it also provides slight flexibility between the flangew/plenum and the plenum can be removed without removing the fuel system!,the pipes inside are around 1mm apart so theres no real interuption in airflow...plus i think they look good...

As for the exhaust manifold,yeh its by no means the coolest looking...but it does have the features i wanted which where strength,clearance and looks like we got away with decent flow as well;)
It will be blasted and ceramic coated black...once installed it can hardly be seen!

thanks, its done in antique steel...the camera does wierd things to the colour...even though i have the white balance set right!!,its a gunmetal colour but when the light shines on it has silver fleck so looks quite cool in the flesh...

laters mang
Paul

lol.. well il take that manifold of your hands!! but I really doubt your motor will blow.. its seems pretty built dude!
thats a petty good idea actuallt.. easy to remove the top half of the manifold without removing the entire intake manifold with injectors. you so smart!
yeh I guess the blue connectors would make any difference.. add a bit of colour to.. too much polished metal!! you getting the metal coated in anything.. painted?
actually.. looking at the new exhaust manifold and seein the pic of the old one.. the new one is way nicer in my opinion. seems like youve gotten further in your build too.. car ready to run yet???!!
cool.. the antique steel finish on the spark plug cover is hella nice.

so any further a long in the build.. from the pics it looks like its ready to run!

[Pagz]

Thanks Ross,spm16vbenz,
yeh its happening...need more money as usual,if you look closely at the engine bay you will see many many things missing like fuel system,wiring,vent/water tanks,exhaust,intake,oil feed,water feed,vaccum lines,throttle cable...enough to keep me more than busy!...im trying to get it done as fast as possible though!;)

laters,
Paul

[crazy00c230k]

holy crap, i dunno how i missed this thread for so long, but the car is looking great, love the rims, cant wait until its done

[Cru328prod]

im like confused, did you take the supercharger out? or is it a non k w202? I WANT IT FOR MY CARRRRRRRR.......IT ALL NEEDS TO BE PUT INTO PRODUCTION!!!!!;) I'D BUY IT

[Pagz]

Originally posted by Cru328prod
im like confused, did you take the supercharger out? or is it a non k w202? I WANT IT FOR MY CARRRRRRRR.......IT ALL NEEDS TO BE PUT INTO PRODUCTION!!!!!;) I'D BUY IT

Hey,
Thanks;)...yes the car once was a C230K,we removed the SC in favour of a turbo setup.
Unfortunatly it would be extremely expensive to replicate this setup,it would also have to be sold with a programed stand alone ECU system as it does away with the DBW and MAF.
but your welcome to use the examples and start your own;)

Laters,
Paul

[spm 16v benz]

hye 23K,

What fuel system computer are you running on your car? and does it run/operate off the inlet camshaft actuator?

Thanks

[Pagz]

Hey,
I have a Motec M400 to install in the following weeks,it will switch the intake cam at the two factory set switch points for the time being...will experiment a bit more when its all up and running!.

If you were refering to the cam reference signal then yes it operates of that.

Paul

[Pagz]

I perminately installed the intake manifold this weekend,so to cap off this thread heres a few pics....

Heres the machine work,the wooden look fuel rail stands are...not wood,we used "phinolic"(spelt right?) material which is sort of like a roll of fabric infused with a resin of sorts...its very strong,doesnt conduct or expand much under heat,so the rail stays as cool as possible,still need to make a couple of washers to go under the bolts.
We machined a couple of brakets into flange to hold the FRP and wiring harness,with a spare in the middle just in case it was needed.
the OE gaskets fit well.

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_333_full.jpg

Fittings welded to the under side of the plenum,brake booster,bov,map,frp,sensors,random pipe into cabin plus a spare.
intake air temp sensor is mounted just after TB.The brake booster,sensors and random pipe into cabin go via the fire wall which imo was the coolest part of the whole install=)

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_336_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_327_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_328_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_331_full.jpg

Flange in position...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_334_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_332_full.jpg

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_337_full.jpg



Second coolest part of the install,the IC pipe leading up to the intake manifold,the only part that wasnt machined to size was the 60mm mandrel bend...the adapter from 60-72 was made from billet,while to rest was machined inside and out to get the desired size,the rest of the IC piping was done the same bar one bend on the hot side of the IC,and because it was all machined we made a rib at each join as well...

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_335_full.jpg


All in a done...=) =)

http://memimage.cardomain.net/member_images/3/web/735000-735999/735658_338_full.jpg


Laters,
Paul

[SLAMMED_C]

WOW Paul.. that is one clean install.. so much attentin to detail. I hate having an engine bay full of wires and hoses, just so much nicer to have a nice clean engine bay, all you need to see is that engine, turbo, and wiked lookin intake manifold!!
great job.. those fittings going through the firewall are pretty trick.. nice.

great job man.. awesome work.
Thanks for teh congrats!.. its been way too long to get my license. but Im finally done and fully qualified. now its time to make money!! have to get good before ya can get fast though. so there will be somewhat of a learning curve, but I dont expect to do too badly at all.

[RacerXofFL]

Patience...:Paranoid:

wow... if only I had half of your patience... if I did id have the right tranny cross member, or a dozen other detail items I've skipped on my own car. This is one of the best done benz's I've ever seen, raied in a benz dealer and so close to renntech, that's saying a lot.

Congratulations. you look closer then ever.

[spm 16v benz]

So who do I make the check out for the engine????? hahaha, wow dude that is off the chain I hope one day I can get my M111 to look like that.......damn so much power. How much power does it have?

[c280nz]

very comprehensive pics you have there,
this thing is just a work of art, talk about meticulus and fussy on the details its outstanding!
man i love that plenum and intake vel stacks!
and the firewall, thats racecar material

side note
im jelous of were your oil filter is! so easy to get to compared to the m104,

[Pagz]

Originally posted by SLAMMED_C
WOW Paul.. that is one clean install.. so much attentin to detail. I hate having an engine bay full of wires and hoses, just so much nicer to have a nice clean engine bay, all you need to see is that engine, turbo, and wiked lookin intake manifold!!
great job.. those fittings going through the firewall are pretty trick.. nice.

great job man.. awesome work.
Thanks for teh congrats!.. its been way too long to get my license. but Im finally done and fully qualified. now its time to make money!! have to get good before ya can get fast though. so there will be somewhat of a learning curve, but I dont expect to do too badly at all.

Thanks man yeh i tried to keep everything as clean as possible,there was more than a few times i sat back wondering if it was really worth the extra time and effort but seeing the end result has definatly made it worth while!...haha got your PM will let you know shortly=)
hooked the TB cable up last night...the plastic accelerator pedal setup is pretty weak,might have to make a custom alloy one and use bearings etc....but we should get by on the plastic one until after tuning i hope;)

Great to hear you passed!,and if you get a pay rise on top of that than the only means ....more mods hehe,*cough*oh and presy's for the gurl yeh=)

[Pagz]

Originally posted by RacerXofFL
Patience...:Paranoid:

wow... if only I had half of your patience... if I did id have the right tranny cross member, or a dozen other detail items I've skipped on my own car. This is one of the best done benz's I've ever seen, raied in a benz dealer and so close to renntech, that's saying a lot.

Congratulations. you look closer then ever.


Patience,haha....its one thing iv never had,but its definitely needed =)...thanks its almost running so close i can smell it,or maybe thats the stale fuel i pumped from the tank heheh it had gone yellow=)

[Pagz]

Originally posted by c280nz
very comprehensive pics you have there,
this thing is just a work of art, talk about meticulus and fussy on the details its outstanding!
man i love that plenum and intake vel stacks!
and the firewall, thats racecar material

side note
im jelous of were your oil filter is! so easy to get to compared to the m104,

Cheers logan,theres alot of short cuts i could have taken...kinda glad i didnt as its likely i would have changed it to how it is now anyway!.
...Im definalty not planning another project like this for some time lol.

Wheres the oil filter on the m104?..yeh the M111 is great...best filter setup iv owned!....try a honda one under the intake manifold,garanteed oil spillage on the side of the engine and all over the subframe and steering=)




So who do I make the check out for the engine????? hahaha, wow dude that is off the chain I hope one day I can get my M111 to look like that.......damn so much power. How much power does it have?

thanks,Haha it may not run yet...its probly siezed=),will not know how much power it will make until we get it tuned in the following weeks...iv just finished the engine loom,still need to tidy up a few loose ends and we should be ready to go!.


Cheers,
Paul

[SLAMMED_C]

Originally posted by 23K
Thanks man yeh i tried to keep everything as clean as possible,there was more than a few times i sat back wondering if it was really worth the extra time and effort but seeing the end result has definatly made it worth while!...haha got your PM will let you know shortly=)

Great to hear you passed!,and if you get a pay rise on top of that than the only means ....more mods hehe,*cough*oh and presy's for the gurl yeh=)

well ya did a great job of keeping it clean.. looks awesome. love that colour on the valve cover too. just looks hotttt! those trick bits made it definetly worth while mang.
lol.. nice, Ill await your reply to my pm!!

I know.. Its such a relief to have passed, and I will see a slight pay raise. lol.. maybe more mods for the car.. its starting to get really tough to spend money on my car.. is it worth while.. ya know. still want that motor swap!! and of course presy;s for my girl.. she wouldnt have it any other way!

[Pagz]

Originally posted by SLAMMED_C
well ya did a great job of keeping it clean.. looks awesome. love that colour on the valve cover too. just looks hotttt! those trick bits made it definetly worth while mang.
lol.. nice, Ill await your reply to my pm!!

I know.. Its such a relief to have passed, and I will see a slight pay raise. lol.. maybe more mods for the car.. its starting to get really tough to spend money on my car.. is it worth while.. ya know. still want that motor swap!! and of course presy;s for my girl.. she wouldnt have it any other way!

This is hard...but honestly i wouldnt spend anymore on your 202...save the money for your own house or you and your gurl...my next project is to spend more on "us" rather than all on my car lol...

...its fun now,but in the long run....=)

[SLAMMED_C]

Originally posted by 23K
This is hard...but honestly i wouldnt spend anymore on your 202...save the money for your own house or you and your gurl...my next project is to spend more on "us" rather than all on my car lol...

...its fun now,but in the long run....=)

I know.. Im slowly thinkin it myself, stop spendin on the w202!.. just finish off everything I have. but Id still like a couple more go fast goodies.. I think it would be too expensive to swap engones, so maybe a couple more go fast goodies and Im done.. finish off the outside and just enjoy a clean car.

oh no worries on that one.. I spend on my girl. but indeed saving for a house still.

[Pagz]

Originally posted by SLAMMED_C
I know.. Im slowly thinkin it myself, stop spendin on the w202!.. just finish off everything I have. but Id still like a couple more go fast goodies.. I think it would be too expensive to swap engones, so maybe a couple more go fast goodies and Im done.. finish off the outside and just enjoy a clean car.

oh no worries on that one.. I spend on my girl. but indeed saving for a house still.

yeah man just finish of all those little jobs,it will clean her up nicely!,then enjoy=)...but...........maybe just an SS header as well hehe=)

[Pagz]

Originally posted by omeyhomey
Paul,

Top notch! 10/10! :cool: :D . I think its safe to say you officially have the coolest 230K on planet earth :) . The quality is amazing and craftsmanship is top notch (and thats coming from me :D ). Congrats & enjoy!


Hey Omey,
Thanks!,thats a big call=),have to say i favour the look of that black C36 with the gold alloys over mine,if it goes missing and ends up with a turbo 4 banger you'll all know why:D hehehe

[SLAMMED_C]

Originally posted by 23K
yeah man just finish of all those little jobs,it will clean her up nicely!,then enjoy=)...but...........maybe just an SS header as well hehe=)
lol.. yeh Iknow.. too many lil things to finish off!!
and yes.. the ss header is tempting, but i want custom!!