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W124 dailydriver upgrade
Sultzi Offline
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#1
W124 dailydriver upgrade
Hi!

Had previosly w123 and om606+722.626 as a daily for a year and then I sold pretty much all of the expensive parts away to get money to another project and bought this standard 300dt 124 with aircon and tempomat. But don't like to drive this, so low on power. I still have the base engine left from w123 so will put that to this and just rebuild and strenghtened 320cdi 722.626 box for this too.

Already I have installed olefejers controller to the car and it now controls w126 electric speedo in w124 dash, speed is taken from front abs sensor. In couple of weeks I install the gearbox itself to the car and in the summer time I change the engine too.

I have bought already 7.5mm pump from dieselmeken and couple of turbos. Exhaust side of those is now done, not by me, PTRacing made all the manifolds for this. He had w124 halfcut in his garage to make turbos fit nicely to w124 engine bay.

Couple of pics..

The car itself last summer
[Image: _medium.jpg]

Donor gearbox was in really bad shape
[Image: _medium.jpg]
[Image: _medium.jpg]
[Image: _medium.jpg]
[Image: _medium.jpg]

Turbos
[Image: _medium.jpg]

Bought chinese made 3" cutout which will be controlled by tcu by boost reference
[Image: _medium.jpg]

Manifold fabrication by PTRacing
[Image: IMG_4960_zpsmxommc1b.jpg]
[Image: IMG_4963_zpssqcczdxk.jpg]
[Image: IMG_5013_zpswqkhnvyg.jpg]
[Image: IMG_5018_zpslvg7p5wz.jpg]
[Image: IMG_5020_zps3rkqlh16.jpg]
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[Image: IMG_5031_zpsw1sscoit.jpg]
[Image: IMG_5066_zps4pyas6is.jpg]
[Image: IMG_5040_zps4ag6cj2t.jpg]
[Image: IMG_5047_zps5etdgvwn.jpg]

[Image: IMG_5041_zpshd4q9jyl.jpg]
[Image: IMG_5054_zpsp4b8xmya.jpg]

Will update more when something happens..
02-14-2016, 05:34 AM
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Duncansport Offline
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#2
RE: W124 dailydriver upgrade
That's a very nice compact set up you've got there. Well done!
02-14-2016, 10:54 AM
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PedroFerreira Offline
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#3
RE: W124 dailydriver upgrade
you keep tempomat working no om606? easy joob?
02-14-2016, 09:00 PM
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Max Offline
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#4
RE: W124 dailydriver upgrade
Very nice Compound Setup  Big Grin


Greets

Max
______________________________________________________________
93´ W124 300TDT -> OM606.962 / RS 203 Dieselmeken 7,5mm 210cc / KKK K14 / Stock Transmission / 2,65 ASD
89´ 190D 2.5 Turbo -> OM605.960 / Dieselmeken 7,5mm 180cc / Holset HX30 Super / 716. 654 6-Speed / 2,87 Rear Axle
02-15-2016, 05:35 AM
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Tito Offline
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#5
RE: W124 dailydriver upgrade
I'm digging the manifold  Cool
(This post was last modified: 02-15-2016, 06:29 AM by Tito.)
02-15-2016, 06:29 AM
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Sultzi Offline
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#6
RE: W124 dailydriver upgrade
Thanks, It came out very nice. Happy that ptracing was intrested of the project to do those manifolds at very reasonable price.

Working on the tempomat at the moment, I have installed olefejers box and it controls now w126 speedo in w124 dash.
02-15-2016, 03:09 PM
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Hario' Offline
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#7
RE: W124 dailydriver upgrade
BWAAAA!

What is a tempomat? Does it cook chicken?



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-18-2016, 11:31 AM
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Petar Offline
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#8
RE: W124 dailydriver upgrade
(02-18-2016, 11:31 AM)Hario Wrote: BWAAAA!

What is a tempomat? Does it cook chicken?

Cruise control lol
02-19-2016, 10:16 AM
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Sultzi Offline
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#9
RE: W124 dailydriver upgrade
Made bracket and modified lever in the tranny to work with BMW steptronic gear stick
[Image: _medium.jpg]

Also oil returns made from 18mm stainless
[Image: _medium.jpg]

And couldn't resist of putting all together
[Image: _medium.jpg]

Now waiting for oil feed parts so I can make the lines too. Will make all the egt and wastegates pipes from 6mm stainless pipe and route them to back of the head where I continue with 4mm air hose..
02-21-2016, 03:45 PM
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whipplem104 Offline
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#10
RE: W124 dailydriver upgrade
Very nice. So it looks like you are planning on running the wastegates for improved a/r. I would guess this because of the size of the gates.
Will be neat to see it on a dyno.
02-21-2016, 05:41 PM
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Sultzi Offline
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#11
RE: W124 dailydriver upgrade
I made all the lines for the wastegates and for egp from 6mm stainless steel pipe and quick connect fittings at the end for 4mm air hose. They came up pretty good i think..

[Image: _medium.jpg]
[Image: _medium.jpg]
02-24-2016, 12:46 PM
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Hario' Offline
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#12
RE: W124 dailydriver upgrade
Sick..



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-25-2016, 04:47 AM
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seanyt Offline
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#13
RE: W124 dailydriver upgrade
For a moment I thought you where using a BMW gearbox.
But now I see the shifter is just BMW.

This is an awesome project. I love the fabrication of the
Manifold and lines beautiful work.
02-25-2016, 04:56 AM
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PedroFerreira Offline
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#14
RE: W124 dailydriver upgrade
love that...
02-25-2016, 06:33 AM
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Lucian189 Offline
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#15
RE: W124 dailydriver upgrade
A realy nice setup,nice welds also
03-03-2016, 02:48 PM
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Keino Offline
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#16
RE: W124 dailydriver upgrade
Nice job!!! Looks awesome

Keep posting Big Grin
03-03-2016, 03:29 PM
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Sultzi Offline
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#17
RE: W124 dailydriver upgrade
Thank you all!

Today I drove first 30km with the reinforced 722.6 and olefejers box. Works nice, just needs little bit adjusting to get all the changes just like i want. But example 3-4 change, no flare at all at anytime yet, so that's nice.

Also tempomat now works with hall sensor mounted to read output flange on the tranny.

Mounted universal 13row cooler where this car originally had tranny cooler (which had broken sometime of the car life and replaced with hose)
[Image: _medium.jpg]

Tranny and hall sensor all in place with bmw gearlever..
[Image: _medium.jpg]
03-06-2016, 12:21 PM
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Tito Offline
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#18
RE: W124 dailydriver upgrade
You're not afraid any rocks or chips will wreck that tranny cooler?
03-06-2016, 01:46 PM
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Sultzi Offline
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#19
RE: W124 dailydriver upgrade
There is original inner fender to cover that up, just took picture without it.

But w123 ex dailydriver had coolers front of the tyres, no problems from rocks or any..
[Image: _medium.jpg]
03-06-2016, 04:01 PM
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Hario' Offline
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#20
RE: W124 dailydriver upgrade
Hey mate do you have no issues with stones on the cooler fins like you say? I'm installing exactly the same!

I'm thinking W210 style plastic inner wing shield type things cut out the oil cooler aperture for additional safety against leaks.

[Image: atf1.jpg]

[Image: atf8.jpg]

Beers!



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 03-07-2016, 10:38 AM by Hario'.)
03-07-2016, 10:38 AM
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Sultzi Offline
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#21
RE: W124 dailydriver upgrade
Didn't have any problems during 17000km what I drove with that w123 without any protection to the coolers (engine and tranny coolers on each side). And the car was my daily, so I drove anywhere Smile But ofcourse anything is possible!
03-07-2016, 02:12 PM
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Sultzi Offline
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#22
RE: W124 dailydriver upgrade
Oil pressure feeds for the turbos now done, an4 ptfe hose. Still needs couple clips to hold them in place, but will do that when engine is finally mounted to the car.

[Image: _medium.jpg]
03-15-2016, 03:31 PM
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maxypriest Offline
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#23
RE: W124 dailydriver upgrade
Stunning work
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
03-16-2016, 05:45 PM
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atypicalguy Offline
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#24
RE: W124 dailydriver upgrade
That manifold is really nice.

What are the compressor wheel sizes and turbine housing A/R on those two turbos?

it looks like you plan to bypass the small compressor at high rpm. Wouldn't it be simpler to just run full compound all the time and use a larger turbine housing on the low pressure turbo? I suppose it depends how much boost you plan to run; sequential could be nice if the large turbo will handle it alone.
03-22-2016, 05:25 AM
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atypicalguy Offline
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#25
RE: W124 dailydriver upgrade
Does PTRACING have a website? Thanks.
03-22-2016, 06:04 AM
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Sultzi Offline
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#26
RE: W124 dailydriver upgrade
Going to run full compound, around 3 to 3.5bars of boost. Can't do any boost pipes until I get the engine to the car. Also will be using garrett 750hp rated water to air intercooler core.

PTRacing don't have website, but you can reach him via pm at http://www.mersuforum.net/forum/memberlist.php?mode=viewprofile&u=12118

Will let you guys know the specs on the turbos when I get the car working with them and know how they perform together. Made all the calculations by myself, so not sure how they will work..
(This post was last modified: 03-24-2016, 11:43 AM by Sultzi.)
03-24-2016, 11:41 AM
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Hario' Offline
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#27
RE: W124 dailydriver upgrade
What sort of PRs have you calculated? As 3.5 bar manifold is about less than PR 3 per stage, seems a bit tame.. Tongue

I guess you'll go more like PR 4 LP and PR 2 HP? Only wondering what your thoughts are

Beers



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
04-12-2016, 06:38 AM
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Sultzi Offline
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Location: Finland
#28
RE: W124 dailydriver upgrade
Total pr with 3bar of boost is 4. Both turbos will be running near 2pr, lp turbo most likely will be 2pr and hp 2-2.5pr where it works better. but i will see what the final result is when i get this working. This is going to be dailydriver, so it can be tame Smile
04-12-2016, 09:58 AM
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Hario' Offline
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#29
RE: W124 dailydriver upgrade
(04-12-2016, 09:58 AM)Sultzi Wrote: Total pr with 3bar of boost is 4. Both turbos will be running near 2pr, lp turbo most likely will be 2pr and hp 2-2.5pr where it works better. but i will see what the final result is when i get this working. This is going to be dailydriver, so it can be tame Smile

Oh yeah sorry don't know what I was talking about



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
04-13-2016, 05:40 AM
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Sultzi Offline
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Posts: 102
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Location: Finland
#30
RE: W124 dailydriver upgrade
Been a while I have updated anything, but been assembling the engine back to one piece.

whipplem104 has been talking here about damper problems and I did look this ones too. There was already marks that damper has been moving around and keyway has come little bit loose. Tapped couple of m6 threads to the damper and crankshaft and assembled it with heavy duty bearing locking fluid. I know this isn't the best way of doing this, but this engine is already seen it's best days so if it goes bananas, I just make new one Smile

Picture of the holes drilled and tapped m6
[Image: _medium.jpg]

Putting the head back on, used Mopar head gasket glue on all survaces, between each layer of head gasket too. Block is honed and head gasket survace also grinded at the same time by the maching shop.
[Image: _medium.jpg]
[Image: _medium.jpg]

Almost done
[Image: _medium.jpg]
[Image: _medium.jpg]
05-15-2016, 04:05 AM
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atypicalguy Offline
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#31
RE: W124 dailydriver upgrade
Wow. You do some nice work. I just went through your build photos on kuvat.fi.

Did you take mercedes wheels and weld new rims to the centers? They look great. And nice new sheet metal also. It will be a great car when you are done.
05-15-2016, 06:13 AM
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Lucian189 Offline
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#32
RE: W124 dailydriver upgrade
Top work!
05-21-2016, 02:23 PM
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#33
RE: W124 dailydriver upgrade
Is the setup working?
07-07-2016, 12:21 PM
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Sultzi Offline
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#34
RE: W124 dailydriver upgrade
Hi, not yet.

Still working with intake and maybe will be swapping the engine while i'm on holiday next month. Will let you know how the setup works when I get it running and tuned.
07-10-2016, 04:21 AM
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atypicalguy Offline
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#35
RE: W124 dailydriver upgrade
Boxing up turbos to send to Pyry.
07-10-2016, 04:49 AM
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Sultzi Offline
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#36
RE: W124 dailydriver upgrade
Nice to hear! What kind of setup that will be?
07-10-2016, 06:13 AM
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atypicalguy Offline
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#37
RE: W124 dailydriver upgrade
He451 over hx30 super.

Holset He451 Part numbers 2837788, 2837789 Original turbo on cummins ISL9 etc Compressor Inducer 64mm Compressor Exducer 93mm Compressor blades: 7+7 Turbine Exducer 64mm Turbine Inducer: 75mm Turbine blades: 12 Turbine housing radius: 6.95cm Turbine cross sectional area: 16cm2 Turbine A/R: 0.9 inches Twin scroll

HX30 super is 46mm compressor inlet. Exhaust housing 6cm

The pump is set to 150cc now but I will probably turn it down to 120 or so. Myna 7mm.

It will take some time to get it all together, but the exhaust manifold is a big piece of the puzzle.

What exhaust valve springs did you use?
Also, what tool did you use to bend the 6mm stainless wastegate lines on your motor? I would like to do that also.

Thank you,
Karl
07-10-2016, 06:41 AM
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Sultzi Offline
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#38
RE: W124 dailydriver upgrade
I bought springs from km racing from norway with bottom plates too. They are reasonable priced.

Springs are http://kmcams.com/products/mercedes-dies...tilfjaerer
and bottom plates http://kmcams.com/products/om606-om605-o...ingfjaerer

I just used 6mm pipe bender, 6mm stainless is still easy to work with.

Intresting to see how that 451 will light up with that hx30, what kind of figures you are after?
07-10-2016, 06:53 AM
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atypicalguy Offline
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#39
RE: W124 dailydriver upgrade
Alone at 120cc the 451 runs right up the middle of the map. Dougal ran some numbers over on 4btswaps. The thread rambles a bit, but you can pick out the best bits. On page 4 he runs the numbers for the 451 and we discuss using a bypass valve for the compressor side (I bought that one Alcaid used from the audi 3.0 biTDI but everyone I know who has tried it cannot get the passive compressor bypass to open, including that guy on here with the compound gwagen). Anyway I am going to run it with a wastegate on each turbo like yours and 50mm gates, and call it good. At 120cc I should not need the 451 wastegate, but if the hx30 compressor is obstructing flow then I will need to wastegate the big turbo and run the little turbo gate at higher pressure. If I want to turn the fuel up later to 150cc I will just turn the hx30 wastegate up to 60psi from 40psi and keep the big turbo gate closed.

http://www.4btswaps.com/forum/showthread...edes/page3
07-10-2016, 10:34 AM
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atypicalguy Offline
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#40
RE: W124 dailydriver upgrade
Sorry I didn't mean to kill the thread. Look forward to hearing more about your build. Regards, Karl
07-13-2016, 07:20 PM
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Hario' Offline
C300TD Wagon (W202)
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Posts: 896
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#41
RE: W124 dailydriver upgrade
(07-10-2016, 06:53 AM)Sultzi Wrote: I bought springs from km racing from norway with bottom plates too. They are reasonable priced.

Springs are http://kmcams.com/products/mercedes-dies...tilfjaerer
and bottom plates http://kmcams.com/products/om606-om605-o...ingfjaerer

I just used 6mm pipe bender, 6mm stainless is still easy to work with.

Intresting to see how that 451 will light up with that hx30, what kind of figures you are after?

Really like the home made hard lines! Really gives it a professional touch compared to miles of braid and hydraulic line.

I notice you're using normal 9ish) gauge exhaust tube for the manifold, have you considered any kind of bracing? I see your turbos are modern and I guess relatively light compared to boat anchor Holsets we use..

Beers.



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
07-14-2016, 10:08 AM
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atypicalguy Offline
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#42
RE: W124 dailydriver upgrade
(07-14-2016, 10:08 AM)Hario Wrote:
(07-10-2016, 06:53 AM)Sultzi Wrote: I bought springs from km racing from norway with bottom plates too. They are reasonable priced.

Springs are http://kmcams.com/products/mercedes-dies...tilfjaerer
and bottom plates http://kmcams.com/products/om606-om605-o...ingfjaerer

I just used 6mm pipe bender, 6mm stainless is still easy to work with.

Intresting to see how that 451 will light up with that hx30, what kind of figures you are after?

Really like the home made hard lines! Really gives it a professional touch compared to miles of braid and hydraulic line.

I notice you're using normal 9ish) gauge exhaust tube for the manifold, have you considered any kind of bracing? I see your turbos are modern and I guess relatively light compared to boat anchor Holsets we use..

Beers.

Yes I am going to copy the bent 6mm lines also for sure. That is a great idea.

The he451 is very heavy. I have not weighed it, but it feels heavier than an injection pump. I am sort of depressed about that, but I suppose any large turbo would weigh quite a lot, and the shaft thickness etc are probably better than a lighter turbo would be.

Ayone here have an opinion about what size wastegate I should be using if I want to bypass like 60% of small turbo flow at 60 psi and 150cc?
07-16-2016, 09:38 PM
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Sultzi Offline
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#43
RE: W124 dailydriver upgrade
I haven't plan to do any supports for the manifolds, atleast yet. They do last when done properly Smile

Still working with the inlet manifold, will give you pictures when I get it done! Will be 3laminova cores inside n/a 606 manifold Smile
07-23-2016, 03:43 AM
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Sultzi Offline
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#44
RE: W124 dailydriver upgrade
Okey, inlet manifold now almost done, only need to make plug adaptors to hold the laminova cores inside the tubes. All welding is done.

om606 n/a inlet manifold cut open
[Image: _medium.jpg]

Inner parts
[Image: _medium.jpg]

Some welding and milling done
[Image: _medium.jpg]
[Image: _medium.jpg]
[Image: _medium.jpg]
[Image: _medium.jpg]

Final welds done
[Image: _medium.jpg]
[Image: _medium.jpg]
[Image: _medium.jpg]
07-31-2016, 02:48 AM
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atypicalguy Offline
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#45
RE: W124 dailydriver upgrade
Looks great. Was it hard to weld to the cast aluminum?
07-31-2016, 02:06 PM
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Sultzi Offline
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#46
RE: W124 dailydriver upgrade
Friend of mine did all the welding, but mb cast intakes are good material to weld with cast suitable welding rod.
07-31-2016, 02:31 PM
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EmJay Offline
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#47
RE: W124 dailydriver upgrade
Not sure that I understand the intake design. What's with the tubes?
1987 Mazda B2200 "outlaw" **planning phase**  Chevy 283, Power Pack heads, Edelbrock carb and intake, turbo 350 trans Smile
1985 Mercedes 300D stock for now
07-31-2016, 08:51 PM
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EmJay Offline
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#48
RE: W124 dailydriver upgrade
Nevermind my previous post as I your other post and looked up what those cores were. Impressive design and idea!
1987 Mazda B2200 "outlaw" **planning phase**  Chevy 283, Power Pack heads, Edelbrock carb and intake, turbo 350 trans Smile
1985 Mercedes 300D stock for now
07-31-2016, 09:11 PM
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maxypriest Offline
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#49
RE: W124 dailydriver upgrade
Loving this, nice plenum design too.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
08-04-2016, 10:57 PM
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atypicalguy Offline
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#50
RE: W124 dailydriver upgrade
Is the idea with top and bottom lines on wastegate to run boost to open and then regulate boost to the other side of the diaphragm to fine tune the opening pressure? If so, what regulators do people usually use?
08-05-2016, 02:30 AM
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