W124 goes om606 - HX40 Billet - 500HP Goal

W124 goes om606 - HX40 Billet - 500HP Goal - Printable Version

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W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 12-26-2015

Hello my friends. To dont mix it up with my old om603 Project (Dynoed 333HP 600nm @1.3 Bar) here is a new thread.

The Basis will be an om606, for now with stock internals. I will do a head porting in summer. I also will use the 606 N/A intake camshaft.

The goal (without cam and Porting) is 500HP, and that with an very good spool on turbo. So what Turbo do i use? I got an HX40W with the small 14cm exhaust housing and billet compressor wheel. I saw an Dynopaper from some HX40 14cm doing around 450 HP. Lets see what we can do.

The Turbo got an 56mm inducer and 85mm exducer. The high trim will help on fast building up Boost. Otherwise the 56mm inducer has just the right size to deliver enauth air for the 500 HP. I see many people do oversizing theier turbos very much. I dont like it because you waste so much early spool potential.

In my opinion the Downpipe is very important. The turbine can only power up the compressor if the exhaust gas can excape very quickly. I do use the internal Wastegate because i like it simple in some way.

Downpipe will be 3,5" going into my 3" exhaust mainfold. Here are a few pictures how hot side of the turbo looks like:

I rebuild it in inventor to see how to best fit the downpipe. This is my solution. I dont like that wastegate exit goes into the small housing of the turbine (66mm) So i will modify the flange plate. First of all this is the flange. I will cut in a phase to go from 66mm to 76mm (3") Also the cut out to wastegate will be done.

Welded onto this will be an 3" to 3,5" pipe with an litte 30mm peace to cover the Wastegate hole.

From this 3.5" i will go 0.5m of downpipe and will go back to my 3" exhaust again.

Thats all for today. I will build this in the next weeks, after that the next step is the exhaust mainfold Smile

RE: W124 goes om606 - HX40 Billet - 500HP Goal - MFSuper90 - 12-26-2015

Looks like it will be a pretty cool build! Are you going to retain the 716 trans you were using before?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 12-26-2015

Thanks!

Yeah i will keep that box. I think it will hold! Hansebanger got +700nm and its no problem until now. I hope its okay with clutch, if not i have to upgrade to 765 Sachs.

Here a few more pictures with V-Band added. I want to go back to 3" before ground to keep the clearance to the ground as good as possible.
Im currently looking out for an exhaust mainfold. I saw KKD Motorsport is making some for good pricing. I thought i read something around 700 Euro. Anyone has one of his mainfolds?
They have 38mm size as i read, and can be ordered in 42mm if wanted. I think i would go for the small one then, eaven if 38mm is not so big for 0.5l

RE: W124 goes om606 - HX40 Billet - 500HP Goal - whipplem104 - 12-26-2015

Yeah we got one and everything was warped and did not fit the car but other than that pretty good. You get what you pay for. But they could not even bother decking the turbo flange so it was flat. And I mean it was really warped. The turbo would never have sealed. I had to use a belt sander on it and take about an 1/8" from it to get it to be close enough to use. The flange to the head can be pulled in with the bolts but it is not much better.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 12-27-2015

How much space do you have at hot side for the mainfold? can you mabe make me a picture?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - whipplem104 - 12-27-2015

I have lots of pictures on my build thread. Here.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 12-27-2015

Yeah i see thanks, did you took 38 or 42mm version?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - whipplem104 - 12-27-2015

Wastegates are 38mm. The A/R is big enough on the turbo that I do not expect to have to open them up much up top to prevent boost creep.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 12-29-2015

I ment exhaust mainfold pipe diameter Smile

I just ordered a CNC exhaust Flange for om606 and the collector because its the most difficult part to make by yourself. Big thanks to DieselPumpUK for making this happen.

The rest of the mainfold i will make by myself. If will be fully stainless, i cant wait for the nice gold color when its used.

Today i machined the internal wastegate bigger. I sealed the turbo with butter, its easy to remove and if you cant remove everything its no problem because it can burn. I did this on serval 2stroke bike engines in the past.

It was 20mm stock and now i machined it to 22mm (20% bigger area). Thats still very small but lets see what it can handle. On my hx35 i also used internal wastegate and i had no problems with not flowing enauth.

I made the hole a bit oval because the valve dose not sit in the middle...

Parts for downpipe are here.

Tomorrow i start to swich oil filter housing on 606 so it can fit into my om603. One of the many things have to be done....

RE: W124 goes om606 - HX40 Billet - 500HP Goal - whipplem104 - 12-29-2015

42mm od.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 01-04-2016

I guess nobody has any opinions about the exhaust turbine size. Seems like you could ask someone on youtube with an hx40 what they used. Or just ask alcaid, as he seems to have good ideas about turbine flows.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - EDH_Performance - 01-05-2016

One friend in Norway dynoed his 606 @ 525hp / 840nm on the wheels with HX40super (60mm inducer) 18cm housing... That was max what that hx40super could do Big Grin

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 01-05-2016

525 Wheel HP should be around 600 Engine HP. Thats heavy! But when did 18cm housing spool?

If i gonna get around 430 Wheel HP (~500 Engine) its fully okay.

How much Boost did he run?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - Tito - 01-05-2016

(01-05-2016, 08:50 AM)EDH_Performance One friend in Norway dynoed his 606 @ 525hp / 840nm on the wheels with HX40super (60mm inducer) 18cm housing... That was max what that hx40super could do

Woah... What would the next step be for more power? HX52? Do they have the same flanges???

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 01-05-2016

(01-05-2016, 08:50 AM)EDH_Performance One friend in Norway dynoed his 606 @ 525hp / 840nm on the wheels with HX40super (60mm inducer) 18cm housing... That was max what that hx40super could do

How much fuel was that pump set up for in cc/1000/injector?

And do you know what rpm was max hosepower?

Thanks.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 01-25-2016

My Project will begin at first week of feburary. In the last days i odered things i really needed.

I orderd 1.5m and 20pc of 90° angles of 42.4mm pipe for my exhaust mainfold build. Im currently waiting for my package from DPumpUK with my Collector and exhaust flange for building the mainfold. Thanks to them!

If anyone want my old HX35W clone feel free to contact me. Im looking for 200 Dollar. Ask for shipping. Its ready to connect to a intercooler, Twinscroll T3 Flange.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - mcwfxx - 01-25-2016

Oooh Swatmugga, how much is flange and collector from DPUK? sounds like a good option! :-)

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 01-25-2016

Please ask DPumpUK for that Smile

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 01-26-2016

(12-27-2015, 11:39 AM)whipplem104 I have lots of pictures on my build thread. Here.

That link doesn't work for me. Can u please repost?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - raysorenson - 01-26-2016

Is that a T4 flange?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - whipplem104 - 01-27-2016

(01-26-2016, 06:51 PM)atypicalguy
(12-27-2015, 11:39 AM)whipplem104 I have lots of pictures on my build thread. Here.

That link doesn't work for me. Can u please repost?

It is just titled W124 build. I did not provide a link. In this section though.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-04-2016

Tomorrow i will start the Transformation. Here i have a little Time-Table whats planned.

First Day Friday:
- Get the car and om606 to my workshop
- Get an overview over all parts i also took there (thats a really lot)

Second Day Sunday:
-Remove om603 from Car.
-Build all parts needed for om606 to the engine.
--> Oilpump
--> Oilpan
--> Dieselpump / steering pump
--> Engine mounts
--> xyz....
--> Weld coones to the exhaust flange (i will do this when its mounted to the block to get as less bending as possible)

Third Day: Monday.

- Mount Engine to the car.
--> Connect Glowplugs
--> Connect negative pressure lines
--> Try to set up a throttle setup
--> Begin with the work of the exhaust mainfold.

4th Day Tuesday

- Weld the exhaust mainfold.

5th Day Wednesday

- Mount the turbo
--> Pressure and reverse line for oil
--> get first engine run
--> Build downpipe

6th Day Friday
--> solve upcoming problems Big Grin

You can look forward to get a lot of pictures Smile

RE: W124 goes om606 - HX40 Billet - 500HP Goal - erx - 02-04-2016

Last year I used hx40 on my om606 and it made 433hp/716nm from wheels. Engine was stock and never opened, custom made manifolds and water meth injection. Turbo was with 16 housing(16 housing was from another turbo and machined to fit, originally it came with 22 housing), intake compressor 8 blade wheel 58/82mm, exhaust turbine wheel 67/76mm.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - PedroFerreira - 02-04-2016

erx what boost to make 433hp?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-04-2016

u sure with that 58mm inducer? i only know from a 54 mm inducer (with 82mm ex) from a normal hx40

433 wheel hp are pretty impressive... that are at least 500 engine HP

RE: W124 goes om606 - HX40 Billet - 500HP Goal - MFSuper90 - 02-04-2016

A lot of the hx40s here in the states are 58mm.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 02-04-2016

(02-04-2016, 05:17 PM)erx Last year I used hx40 on my om606 and it made 433hp/716nm from wheels. Engine was stock and never opened, custom made manifolds and water meth injection. Turbo was with 16 housing(16 housing was from another turbo and machined to fit, originally it came with 22 housing), intake compressor 8 blade wheel 58/82mm, exhaust turbine wheel 67/76mm.

Does 16 housing mean A/R of 1.6, or area of 16cm2? Trying to figure out how big the housing is on an he451 non-vgt and it has 16 stamped into the metal. Thanks.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-05-2016

(02-04-2016, 09:46 PM)MFSuper90 A lot of the hx40s here in the states are 58mm.

yes but ive never seen a 8 blade one

RE: W124 goes om606 - HX40 Billet - 500HP Goal - erx - 02-05-2016

(02-04-2016, 10:06 PM)atypicalguy
(02-04-2016, 05:17 PM)erx Last year I used hx40 on my om606 and it made 433hp/716nm from wheels. Engine was stock and never opened, custom made manifolds and water meth injection. Turbo was with 16 housing(16 housing was from another turbo and machined to fit, originally it came with 22 housing), intake compressor 8 blade wheel 58/82mm, exhaust turbine wheel 67/76mm.

Does 16 housing mean A/R of 1.6, or area of 16cm2? Trying to figure out how big the housing is on an he451 non-vgt and it has 16 stamped into the metal. Thanks.

16cm2. 8 blade is rare, it was already swapped to 16cm2 when I bought it. 8 blade should be able to make a little higher boost pressure than 6 and 7 blade but it flows a little less.
433whp came with 3 bar, it was smoking on high revs so it felt like turbo was working on its' max limit, I upgrade to hx52 at the moment.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-07-2016

First day is done!

Engine is out of the car. I already took of all Parts i need including the oil pan and pump.

Tuesday i gonna go forward with installig all things on om606. Plan is to get the engine installed at the evening.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 02-07-2016

(02-05-2016, 12:46 PM)erx
(02-04-2016, 10:06 PM)atypicalguy
(02-04-2016, 05:17 PM)erx Last year I used hx40 on my om606 and it made 433hp/716nm from wheels. Engine was stock and never opened, custom made manifolds and water meth injection. Turbo was with 16 housing(16 housing was from another turbo and machined to fit, originally it came with 22 housing), intake compressor 8 blade wheel 58/82mm, exhaust turbine wheel 67/76mm.

Does 16 housing mean A/R of 1.6, or area of 16cm2? Trying to figure out how big the housing is on an he451 non-vgt and it has 16 stamped into the metal. Thanks.

16cm2. 8 blade is rare, it was already swapped to 16cm2 when I bought it. 8 blade should be able to make a little higher boost pressure than 6 and 7 blade but it flows a little less.
433whp came with 3 bar, it was smoking on high revs so it felt like turbo was working on its' max limit, I upgrade to hx52 at the moment.

How much fuel were you burning with 45psi? 120cc? Hx52 turbine

RE: W124 goes om606 - HX40 Billet - 500HP Goal - erx - 02-07-2016

(02-07-2016, 05:04 PM)atypicalguy
(02-05-2016, 12:46 PM)erx
(02-04-2016, 10:06 PM)atypicalguy Does 16 housing mean A/R of 1.6, or area of 16cm2? Trying to figure out how big the housing is on an he451 non-vgt and it has 16 stamped into the metal. Thanks.

16cm2. 8 blade is rare, it was already swapped to 16cm2 when I bought it. 8 blade should be able to make a little higher boost pressure than 6 and 7 blade but it flows a little less.
433whp came with 3 bar, it was smoking on high revs so it felt like turbo was working on its' max limit, I upgrade to hx52 at the moment.
How much fuel were you burning with 45psi? 120cc? Hx52 turbine

I have 180cc pump but it wasn't screwed to max fuel, i'm not sure but if 180cc is for 600hp then I guess with 500hp it may be 150cc. It was with HX40.
https://www.youtube.com/watch?v=lQ6RRr8fBwA

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-07-2016

Ah i see you have auto gearbox... taking a lot of power Sad

Sure are you sure with 58mm inducer? can you mabe make a picture of your turbo?

_____________

EDIT just looked in your thread lookes like 58mm... Nice Power output, lets see what my build can do.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 02-07-2016

(02-07-2016, 05:42 PM)erx
(02-07-2016, 05:04 PM)atypicalguy
(02-05-2016, 12:46 PM)erx 16cm2. 8 blade is rare, it was already swapped to 16cm2 when I bought it. 8 blade should be able to make a little higher boost pressure than 6 and 7 blade but it flows a little less.
433whp came with 3 bar, it was smoking on high revs so it felt like turbo was working on its' max limit, I upgrade to hx52 at the moment.
How much fuel were you burning with 45psi? 120cc? Hx52 turbine

I have 180cc pump but it wasn't screwed to max fuel, i'm not sure but if 180cc is for 600hp then I guess with 500hp it may be 150cc. It was with HX40.
https://www.youtube.com/watch?v=lQ6RRr8fBwA

Nice video. I think automatic transmission is perfect for high hp and high torque.

Hx52 is much bigger turbine...

What rpm was the peak hp? Seems like the hx40 would max out well before 6000 rpm at 3 bar.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - erx - 02-08-2016

(02-07-2016, 10:20 PM)atypicalguy
(02-07-2016, 05:42 PM)erx
(02-07-2016, 05:04 PM)atypicalguy How much fuel were you burning with 45psi? 120cc? Hx52 turbine

I have 180cc pump but it wasn't screwed to max fuel, i'm not sure but if 180cc is for 600hp then I guess with 500hp it may be 150cc. It was with HX40.
https://www.youtube.com/watch?v=lQ6RRr8fBwA

Nice video. I think automatic transmission is perfect for high hp and high torque.

Hx52 is much bigger turbine...

What rpm was the peak hp? Seems like the hx40 would max out well before 6000 rpm at 3 bar.

Peak hp was on 5300rpm and peak nm on 4500rpm

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-09-2016

Second day is done.

Görans Magig is installed again. Timed 8.5° ATDC

Then i swiched the oil pan. It took me 1.5hour to remove the old gasket from the om603 oilpan.

After that i changed the connectors for the glow Plugs:

I began to machine the exhaust flange. In stock it has a massive edge. But my cutter failed after a few minutes and is dead now .....

I swiched to the intake mainfold and removed these conectors between the cylinders. I like the optical part and otherwise the heat from the engine can better escape.

Thats all for today. Looking forward to sandblast the intake mainfold tomorrow and make the exhaust flange ready. I hope i can begin with the welding on wensday.

BTW This is my 2M Flywheel after 20 000km of STD driving. Massive play need a new one.

https://www.dropbox.com/s/cirsa1c1cjz9b6p/20160209_101937.mp4?dl=0

RE: W124 goes om606 - HX40 Billet - 500HP Goal - Max - 02-09-2016

Good work, keep going.

Greets

Max

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-10-2016

Thanks man!

Exhaust Flange is ready for welding. I gonna sandblast intake mainfold in an hour.

I hope i get the engine installed Tomorrow and first steps of exhaust mainfold building.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-12-2016

Next Day is gone.

om606 is in his new home.

I allready did the main connecting things. Here is my new clutch pressure plate: (left new, right old)

Its from an W210 270 CDI delivers stock 400nm (old Pressure plate was from 220 CDI with 340nm). I hope this will hold ~800nm with my sinter disk.

I also begin with the welding for the exhaust mainfold but did not got so far, only welded the cones on the flange and removed the bending. Tomorrow i gonna set the turbo in place and mabe weld the first cylinder pipe.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-15-2016

Another day is gone. Gearbox and clutch are installed. But the main time i spend today for welding the mainfold.

First of all im not a professional welder and that is the second thing in my life im welding a thing like this.
I like to do the things on my own and not only buying parts togehter and use them im plug and play.

At first i looked for a good turbo position. It shound not collide with the cylinder head and the water tank. Also it should be as low as possible for a better car handling. Keep enauth space for the downpipe is also a thing to look at.

A big thing is done and its now not so much work to get the car running. I look forward to get the car this week ready!

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-19-2016

The car is almost finished now. Only thing missing is the downpipe and the rest of the throttle connector.

https://www.dropbox.com/s/v0te9ln93ixvus2/20160219_163549.mp4?dl=0

In my opinion i got a really clean solution for the pipe to the intercooler. Almost no angles.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - Tobulus - 02-20-2016

That is a really nice solution, much better than the intercooler below the front bumper. Nice build!

RE: W124 goes om606 - HX40 Billet - 500HP Goal - DiseaselWeasel - 02-22-2016

So what's the TÜV engineer got to say about this?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-23-2016

Haha i think he likes it Big Grin

. Was there a month ago.

Finally its done.

After two hard weeks the car is ready. I only made a really short testdrive today. The weather was so bad that i cant see anything.
I dont build a 3.5" downpipe, there was to less space. But i found a really nice 3" solution.

I dont made more picutres today. But the car is ready and i hope i can drive more tomorrow.
Turbo is fucking agressive. I have with 14cm HX40 better spool than the hx35 12cm on om603.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - whipplem104 - 02-23-2016

You have to move the turbo further forward in the engine bay. We got 4" exhaust in the 124 chassis. With external dumps as well.

RE: W124 goes om606 - HX40 Billet - 500HP Goal - swatmugga - 02-24-2016

Yeah i know i thought about it but im very happy with my solution i have.

Today i made the first drive, the Power is insane. Currently im on same fuel level i had on om603 on 1.3 bar with smoke (around 140cc).
Currently wastegate opens at 1.8 - 2 bar and i have wheelspin in 3rd gear on DRY street every time, and in 4th gear somtimes...

I have a little bit of fear to unlock the rest 40cc from my pump, i think that would destroy everything Big Grin

.
When i "leared" how to handle this power i will make a quick video with some 100-->200 kmh timings.

Turbo spools up faster than hx35 with the selfmade twinscroll mainfold. Mabe there will be a video tomorrow Smile

RE: W124 goes om606 - HX40 Billet - 500HP Goal - Bigpanda16 - 02-25-2016

Very cool and interesting build, good work and congratulations!

RE: W124 goes om606 - HX40 Billet - 500HP Goal - PedroFerreira - 02-25-2016

VIDEOOOOS!!!!!!

RE: W124 goes om606 - HX40 Billet - 500HP Goal - atypicalguy - 02-25-2016

(02-24-2016, 06:55 PM)swatmugga Yeah i know i thought about it but im very happy with my solution i have.

Today i made the first drive, the Power is insane. Currently im on same fuel level i had on om603 on 1.3 bar with smoke (around 140cc).
Currently wastegate opens at 1.8 - 2 bar and i have wheelspin in 3rd gear on DRY street every time, and in 4th gear somtimes...

I have a little bit of fear to unlock the rest 40cc from my pump, i think that would destroy everything .
When i "leared" how to handle this power i will make a quick video with some 100-->200 kmh timings.

Turbo spools up faster than hx35 with the selfmade twinscroll mainfold. Mabe there will be a video tomorrow

Nice work there! How is the smoke and what are the egts?

RE: W124 goes om606 - HX40 Billet - 500HP Goal - Tito - 02-26-2016

Nice job! Can't wait for some vids!