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Om605 compound turbo build, my Corolla Ke70 tracktoy - Printable Version

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+--- Thread: Om605 compound turbo build, my Corolla Ke70 tracktoy (/showthread.php?tid=4390)

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RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-07-2013

Simpler; Thanks! Big Grin Very fun to hear! Big Grin

The trannys I have are a 717.411 that I have read that can take quite alot of beating, but that is my secund tranny, the first choice is the 717.435 from 2,6 that I have read that sould take even more beating than the .411 Smile You also must remember that I only have half the wight of an old merc to push around, that makes the job easyer for the tranny Wink

Here are the finish floor

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Also mounted the clutch today, but something went wrong.

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Here are the pressure plate only loose mounted, and it looks fine, but when I tighten the screws the center is pushed in, like its to tight for the clutch. Souldnt it look like on the picture? and not with the senter of the pressure plate pointing inn? Smile

The plan was to put the engine and transmission in on thursday, but now it depends on the clutch.. :/

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 05-08-2013

I've put down a tranny like that in my W123 allready :p
and it's only about 300hp atm, but, it's true what you say about the weight, it's a important
point..
but, I thing you will smash it really quick :p

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-09-2013

witch one did you wreck, .411 or .435? Have read that they should take quite alot torque, and with the car that weights under 1000kg and with random sheep rear tires I dont think the tranny will be any problem Smile the rear tires wil slip before reaching any high torques.

Mounted the clutch today, and then I got the tranny ready, with new fine oil. The old one looked not good, so new oil was needed

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And connected

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And installed in the car again!

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Next big prosjekt is to get the rear axle in place Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 05-10-2013

I tok a 417 i think :p
from a 230e :p

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 05-10-2013

(05-09-2013, 06:03 PM)Stamsaas [Image: 20130509_212456_zps8e4a6d93.jpg]

I'm glad to see that using tires to floor mount an engine is a globally recognized method Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - hansebanger77 - 05-10-2013

Hi. What clutch setup is that? Flat disc?
Dual flywheel?

Difficult to say. It's from pressureplate to pressureplate different. If the spring fingers go to much inside you have not the optimal pressure on disc. Otherwise to less has the same bad effect.

My expiriance with stock flywheel, plate, disc I machined down about 0.3 mm outside for best pressure resault. It's good tuning for soft turbo stock pump. But we all know ne'er hold a superturbo torque. :-)

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - maxypriest - 05-10-2013

(05-09-2013, 06:03 PM)Stamsaas witch one did you wreck, .411 or .435? Have read that they should take quite alot torque, and with the car that weights under 1000kg and with random sheep rear tires I dont think the tranny will be any problem Smile the rear tires wil slip before reaching any high torques.

Mounted the clutch today, and then I got the tranny ready, with new fine oil. The old one looked not good, so new oil was needed

[Image: 20130509_204909_zps6c2629a3.jpg]

And connected

[Image: 20130509_212456_zps8e4a6d93.jpg]

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And installed in the car again!

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Next big prosjekt is to get the rear axle in place Smile

LOVING THIS PROJECT!!!!!Tongue

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-11-2013

(05-10-2013, 03:24 AM)Ksteen2 I tok a 417 i think :p
from a 230e :p
Okay, dont know how that is, but the .411 and .435 are the ones that are talked about what I have seen after googleing alot Smile I bet the wheels have no grip at 300hp Smile

(05-10-2013, 08:32 AM)Simpler=Better I'm glad to see that using tires to floor mount an engine is a globally recognized method Smile
Hehe, yeah, but I never put it down, just had then there because I planer to install the engine a few days after I took it out, and tought it would be much easier to lay it down than hang it up in the enginerack :p

(05-10-2013, 08:59 AM)hansebanger77 Hi. What clutch setup is that? Flat disc?
Dual flywheel?

Difficult to say. It's from pressureplate to pressureplate different. If the spring fingers go to much inside you have not the optimal pressure on disc. Otherwise to less has the same bad effect.

My expiriance with stock flywheel, plate, disc I machined down about 0.3 mm outside for best pressure resault. It's good tuning for soft turbo stock pump. But we all know ne'er hold a superturbo torque. :-)
Hello Smile the clutch is Spec Stage 5, and singlemass flywheel. I got some advise from Mr EDH_performance and spaced out the pressureplate 2mm, than it looked much better Smile

(05-10-2013, 09:37 AM)maxypriest LOVING THIS PROJECT!!!!!Tongue
Thanks! Smile

Got the rear Axel of yesterday, and think i will start the work on the new one today Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - hansebanger77 - 05-11-2013

Nice. Is it self made or plug and play from other engine?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-12-2013

The flywheel is OEM Mercedes and the spec is to Mercedes, but I dont know eksakt wich Merc the flywheels is from. That might have been the problem with the pressureplate Smile

Rear axle is down, here is Ke70 vs Volvo 240

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the 240 one is 1cm narrower without brakediscs, så it is quite perfekt for this car. Got all the old brackets of it

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Time to open it and se, and it have taken som good beating. It has been used on a heavy 240 with 400hp v8, and some of the welding had cracks, and the oil had alot metallic effects :p

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time to get in some new oil :p

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starting on the new brackets

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And finish measuring it up, ready to be welded on. Made them a little longer than the stock, because the car is quite low, to get the bars in more right angle

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brackets on, and axle under the car. Will put it on the lower bars, and do the measuring under there to get the upper bars in correct position

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allso welded over the diff, hoping it can hold one more season Smile To be continued next weekend Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 05-13-2013

If that breaks strike a deal with someone over here to trade manual transmission parts for a dana60. You will have a really hard time breaking a 60 (or fitting it under the car for that matter :p)

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-13-2013

hehe, the axle itself sould take the beating easy, but this was a bit beaten up :p If it holds one season i guess it will be a truetrack diff or something for the net season Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Njdub - 05-13-2013

Amazing build sir. This is what im going for in my Isuzu. You are motivating me to get back into it!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-19-2013

Thanks Njdub! Glad if I can motivate! Smile

Have been some more hours in the workshop now, made some brackets

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Ready to weld

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made the lower arms adjustable

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welding finished

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Last ting on, the spring bowl (or what the name is) is taken from the Ke70 axle, and the fit with the springs I am using. They are lesjøfors from Volvo 240

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Primed

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and painted

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And sealed, ready for oil. Hengig the axle up tomorrow

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Also put on one headlamp today, should just fit with 3" pressure pipe :p

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Got aluminium inntake manifold today also, so a friend is going to weld me a dual plenum inntake Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - maxypriest - 05-20-2013

Duel plennum? I will have to make a plennum soon, thus are looking for some hints and tips on how to make a good design.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-20-2013

Dual plenum

[Image: 9r28fm.jpg]

It should spread the air better to all sylinders. But he couldt do it before a good tide, så I bought TIG welder today, and will try to make my own intake manifold Smile

Today i hang up the rear axle, and this is will be the ridehight

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Perfect fitment

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custom

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Enginebay

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om606 intake vs om605. Syl 4 is the one that must go..

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...and so it was

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this looked a bit high...

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But the hood fits on! Big Grin

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front part of the axle mounted to the gear, and the rear part cut down, ready to be modded to fit with the rear axle Smile

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More parts are also in order Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 05-30-2013

Now, time for a update. Have started on the rollcage Smile

removed some asphalt on the floor

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Main tube in, and all fixing is being made after the Norwegian motorsports rules

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And the hight of it

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But then the hard parts came, to make the tubes to the front, and that the cage have to be lowered down trough the floor. So needed some holes

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Point welded

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When I was happy With the shape, I welded all that I could do from the underside and lowered the cage down to weld the overside

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And back up again

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Got some help from my friend that work in a bodyshop, and we made the boxes to the cage. Made them trough the floor to have jack pionts

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inside

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Welding in progress

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And the other side

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Just to weld the last part, and bok is finished. The bolts are one of the rules, so they just have to be there.

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Now all the 4 boxes are finish, and the cage is welded in them. The worst part is done. Starting on the rear Next time Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 06-09-2013

Long time sinse last time here now! Have done quite much,, so just throwing out some pics of the latest progress Wink

Rollcage comming together

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Done!

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Next ut was to mask up the car, and prime the Cage. Here are also some new rims, that I will use on track. Think I need atleast 6 rear Wheels :p

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Starting to paint the cage, semi matt black

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Painting finish

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And some new "stance" Wheels. I also have a thing for Nice rims :p

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Brock B1 9x16 with a bit to much rubber

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Have gotten a new low profile fan from Spal, and wil redo the fixing for radiator and cooler, and than I can get it in Smile

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Steering colum mounted, and made a bracket, so the oem Toyota ignition is fitted

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And I have tried sandblasting on the manifold. blasted the inside

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Finish looking really good!

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clean!

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Manifold mounted, and EGT sensor mounted, and copper braketube fitted to backpressure measuring

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And made a bracket to the wastegate, since I have rotated the compressorside

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And, that is about it to now Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - lgreeley83 - 06-09-2013

That's it?!?! When are you going to work on this thing?

Just kidding....Great work. Love following this one. Can't wait to see it finished.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 06-11-2013

Neh, not doing so much, mostly sit and look at it :p
Thanks, I almost cant wait either! Smile

Redid the fixing of radiator and cooler, and got the low profile Spal fan between

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Tight anyone?

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Cooler on

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just enought space :p

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RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 06-11-2013

Every clearance is good clearance;-)

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - larsalan - 06-11-2013

that fan both sucks and blows Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 06-12-2013

thats right Haavard, but have to cut out some to get the front plate on :p

Its a sucking blower Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - DiseaselWeasel - 06-12-2013

As long as it doesn't suck at blowing all is fine... Big Grin Awesome project!!!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-02-2013

NOW there have been way to long time since last update here. Have done quite a bit, but I have not had any time to update this.. There is alot, so I just throw out some pics and short describtion.

New vacum stop valve, and bracket made

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And brakelines, all in teflon/steel.

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And New rear discs redrilled and new calipers and pads mounted

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new plate for track use

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And starting on the new Dashboard

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A littlebit paint

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hmm.. little tight, is it? Got it on Smile

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Finish dash

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Wrapped exhaust manifold

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Velded in An10 fittings to the oil housing to oilcooler

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Have allso started the engine in the car Big Grin

http://www.youtube.com/watch?feature=player_embedded&v=5nRHPCT2SRQ

http://www.youtube.com/watch?feature=player_embedded&v=YsMEk1cUla0

Big Grin


And then I got it back on the floor, have been on stands since the autom.

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then it was over in the lifter

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Hopefully I can weld ut the bearing of the midle axle tomorrow.. Saturaday, than its tracktime! Big Grin

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - lgreeley83 - 07-02-2013

Woot! Videos this weekend!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 07-03-2013

nice Wink
veeerry low oil pan, but it is just awesome looking and so mean looking Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - mantahead - 07-03-2013

Coollooking good, nice dash board, was going to make something like that for the merc.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - bruno_pinho - 07-03-2013

Very good ....

Could you tell me where do you get information from rpm?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 07-03-2013

I think a 1/4" (6mm?) skidplate is needed at least

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-03-2013

(07-02-2013, 07:44 PM)lgreeley83 Woot! Videos this weekend!
There will be alot video and pics! ;p

(07-03-2013, 03:09 AM)Ksteen2 nice Wink
veeerry low oil pan, but it is just awesome looking and so mean looking Wink
The oilpan is low, but not as low as i tought. I had lower oilpan on the daily, and that was not so big problems Smile But I really need a front lip of a kind.... Huh

(07-03-2013, 04:14 AM)mantahead Coollooking good, nice dash board, was going to make something like that for the merc.
Thanks. Yes, the original plan was to use the original dash, but is was so easy and clean to just do it like this Smile

(07-03-2013, 07:26 AM)bruno_pinho Very good ....

Could you tell me where do you get information from rpm?
It comes from the "W" on the dynamo. It Works fine, but the rpm klock have to be finetuned, so its not 100% correct now, its just about there on the feeling.

(07-03-2013, 07:51 AM)Simpler=Better I think a 1/4" (6mm?) skidplate is needed at least
Yeah, I think I will make something to take the worst beating :p


New day in the workshop to day Smile
Got Lock?

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enginebay view

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todays work. Midle axle and exhaust

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in the making of the bracket to the midle axle bearing

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and voila

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finished, and I am very happy about the result. got it perfikt in line Smile

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And than the exhaust. Here are the downpipe with the flex joint

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some tight shit around the gearbox, so it will be hanging a bit low past there. Building of 3" from turbo and out

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and the finish piece, ready do be welded

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And the finish welded downpipe

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Moro to come tomorrow Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-04-2013

New day finished, and have got some more shit done Smile

Complete exhaust finish welded

[Image: 20130704_121227_zpse6cd9970.jpg]

And got a bad feeling of the clutch when we tried to bleed it, so tok out the old slave and it was crap. New one ordered, and tok some measures and found out it had to be 40mm longer.

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Downpipe wrapped, and mounted the rest of the exhaust

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so there was the cooler preasure pipes

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was very tight with the standard intake, so this was not the best so have to modify this one. popped the hoses with under 1bar

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Aired the clutch, that worked, and the brakes, and tok it out for a test! Big Grin Big Grin

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have some shit that have to be better, but much also worket out fine Smile very fun to have drove the car!!! Big Grin Big Grin
Here is a little Movie from the test, blows the boostpipe after 2.gear :/

http://www.youtube.com/watch?feature=player_embedded&v=aMUDF0EsgUY

have to do a pumpadjustment tomorrow also Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - winmutt - 07-05-2013

Dont worry about the low hanging exhaust, the oilpan will act as a warning indicator! Great build. Love it.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 07-05-2013

Weld as much as you can of the boost pipes. Booring when they popWink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - mantahead - 07-05-2013

well done, looking good.

think you need little retard on pump

this machine will turn a few heads.Cool

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-05-2013

(07-05-2013, 08:56 AM)winmutt Dont worry about the low hanging exhaust, the oilpan will act as a warning indicator! Great build. Love it.
Sure, no problem with the exhaust :p hehe! Exhaust is touching a bit when driving on gravel, but oilpan is ok Smile but this mainly is a trackcar, so thats no biggie. Thanks Smile


(07-05-2013, 09:38 AM)HaavardPYA Weld as much as you can of the boost pipes. Booring when they popWink
Have swaped all pipes from aluminium to Steel that is welded with sports inside the clamp. Tested now 30 min ago and 1,6bar ish is ok Smile

(07-05-2013, 06:00 PM)mantahead well done, looking good.

think you need little retard on pump

this machine will turn a few heads.Cool
Thanks mate Smile I adjusted the pump abit from the engine today, and the idle is much better, but still thinks it sounds a bit harse when rewing up slowly.. Had the pump out once, and might think it have undone itself when mounted in again Sad
I hope so, going to a japanise trackday tomorrow, so cant wait to see the looks when starting up this Big Grin

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-09-2013

Was on the track Saturday, got the car ready, and did the last little testdrive 03.00 at the night before. Did a stop on the way to fuel it up

[Image: 20130706_103524_zps564eeb09.jpg]

Had some problems, and mainly is that was overheating, and loads of it. Had 100 degrees water after a slow lap.. That combiened with loads og smoke, engine going hard and late spoolup wi desided to time up the pump again, an the track. And so we did, and had to remowe the radiator, enginemount and alda valve to get the pump out, but we got it out and timed. Mounted up the shit, and it fired at the first hit with smooth idle like factory new. Then we hit the track agian, and it worked great! Spool from the buttom, running sweet, and response. the pump was adjusted down quite a bit so not the highest power, but I will guess 120-150hp. Popped a watherhose and boostpipe of turbo after 2.round, and then it was finish for the day. Totaly I am very happy, got the car tested, and got some Things fixed. Smile The clutch sliped some, so must find something there Smile

Here are some pics my Brother took
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And some other pics from facebook Smile

Before timing the pump :p
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Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 07-09-2013

This thing is incredible!!!!

Glad to hear the timing fixed it, and good to see the exhaust wrapped Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - HaavardPYA - 07-10-2013

Love the look of the car!! What's your goal in the tq and hp area?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 07-11-2013

are you going to gatebil this weekend with that car?? Wink
I would love to se it Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-11-2013

(07-09-2013, 03:33 PM)Simpler=Better This thing is incredible!!!!

Glad to hear the timing fixed it, and good to see the exhaust wrapped Smile
Thanks! Big Grin
(07-10-2013, 11:16 AM)HaavardPYA Love the look of the car!! What's your goal in the tq and hp area?
Thanks, I have not any big goals, just that it should be fun Smile but I think 300-350hp can be possible Smile Would rather have 300 and a fine curve of torque than 400 and have to shift up and down all the time. Now its quite good on Rudskogen, mostly only using 3. and 4. gear and the torque Smile
(07-11-2013, 02:36 AM)Ksteen2 are you going to gatebil this weekend with that car?? Wink
I would love to se it Wink
No, car will not be on Gatebil, but the owner will be one day :p but the car is only 10-15min from Rudskogen Wink

And i have bougth new clutch now, machined lightened flywheel with sachs pressureplate and 3 plated tilton discs Smile that should take some beating Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Ksteen2 - 07-12-2013

okei, I'm going too rudskogen on saturday, maybe I can take a look at it?

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-12-2013

We can fix that Wink but need a new coolant hose, so its not driveable atm :/

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - JB3 - 07-14-2013

what a great build!

This think is the equivalent of bolting a V-twin motorcycle engine to a BMX bike. Absolutely awesome

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-17-2013

haha, thanks! Big Grin But I think a v-twin on a BMX is more crazy :p

Tok the car outside for some pics the other day, long time sinse some serious pics

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Starting working on my house so there will be less time on the car.. But got the New clutch and flywheels today Smile

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Simpler=Better - 07-17-2013

Where is the radio!?!?!?!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - winmutt - 07-18-2013

Yes cars need a few basic things: Go, stop, clutch pedals, seats, windows that roll down, sun roofs and music. Everything else is optional.

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - Stamsaas - 07-18-2013

Radio is just unneeded weight Wink Dont want to have anything desturbing the sound of the exhaust and the Holset Wink

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - StrikerofDeath - 07-25-2013

(07-17-2013, 11:30 AM)Simpler=Better Where is the radio!?!?!?!
under the hood...
best not exist!


congratulation!

RE: Norwegian OM605 build -> 1980 Ke70 Corolla - willbhere4u - 07-25-2013

(07-25-2013, 08:22 AM)StrikerofDeath under the hood...
best not exist!

Ditto I can't here the radio in most of my cars anyways. More fun to listen to the engine purr through the gears