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W124 dailydriver upgrade
whipplem104 Offline
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#51
RE: W124 dailydriver upgrade
Cool idea on the intake. But you are trying to run all the air through a relatively small amount of the intercooler cores at the inlet. It might have been better to bypass the cores and go around and just come back in on the way to the runners. How much were the laminova tubes by the way.
08-05-2016, 09:08 AM
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atypicalguy Offline
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#52
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, 07:19 PM
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Sultzi Offline
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#53
RE: W124 dailydriver upgrade
That is true whipplem, been thinking the same thing too, but time will tell how it works.

That's why I have dual temperature gauge after hp turbo and second input after laminovas (near one of the runners). And also will put dual pressure gauge after hp and after laminovas to see what kind of pressure drop it generates. Then we will know Smile Also will put two water temperature gauges to monitor coolant before and after laminovas.

These laminovas were 79$ a piece from ebay, originally they are around 200$ a piece I think. These where new also, somebody is selling big batch away.

Not sure yet how to control the wastegates, I have plummed all the lines for safety, so they are ready if I need any of them.
(This post was last modified: 08-06-2016, 03:35 AM by Sultzi.)
08-06-2016, 03:33 AM
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Sultzi Offline
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#54
RE: W124 dailydriver upgrade
Intake almost done, rest of it I can make when I get the engine to the car. Firewall around brakebooster needs a bit cutting to get that intake fit, but nothing major..

[Image: _medium.jpg]
08-19-2016, 03:14 AM
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maxypriest Offline
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#55
RE: W124 dailydriver upgrade
Loving this build. I hope that the intake flows well.

Using this design you have reduced the intake length nicely and also only have 1 boost hose which is a winner. I’m really interested to see how the compound set up works out too.

Very nice.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
08-22-2016, 08:06 AM
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Sultzi Offline
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#56
RE: W124 dailydriver upgrade
Exhaust done last weekend, came pretty good. Stainless steel naturally.. 4" downpipe, 3,5" to the backaxle and rest of it is 3". Also have 3" cutout out from the fender to be activated by boost or switch

[Image: _medium.jpg]
[Image: _medium.jpg]

Also wg lines installed
[Image: _medium.jpg]

Still need to get intercooler water circulation plumbed and wired and also all the gauges to work so tuning is easier.

Now I have the wastegate setup as this:
-1bar srpings in both wg
-lp turbo has opening pressure coming from the hotpipe between turbos
-hp turbo has opening pressure coming from intake (total boost) with turbosmart bleed in the line
-hp turbo has closening pressure coming from the hotpipe between turbos

This is the first try with controlling the gates, im sure I need to play with them pretty much to get it to work nicely..
09-02-2016, 03:49 AM
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Sultzi Offline
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#57
RE: W124 dailydriver upgrade
Engine bay at the moment
[Image: _medium.jpg]
09-02-2016, 02:21 PM
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maxypriest Offline
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#58
RE: W124 dailydriver upgrade
Keep it going - this is a superb build.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
09-05-2016, 06:51 AM
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Max Offline
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#59
RE: W124 dailydriver upgrade
Really great Work !!

Hope to see it running soon  Big Grin
______________________________________________________________
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
09-07-2016, 04:52 PM
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Sultzi Offline
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#60
RE: W124 dailydriver upgrade
Been now driving and adjusting the wastegates. Currently running 2,7bar of total boost, 1bar at the lp and around 0,85bar at the hp turbo. Backpressure now at 3,5bar (not too much yet). Probably need to change biggest springs to hp wastegate, currently has second hardest installed. It's just pain in the ass to change in situ Big Grin

Boost start to rise around 2000rpm and with converter locked I can get full pressure around 2500-2700rpm. With smaller gears it does go over 3000rpm due no locked converter. Very pleasant to drive! So must be happy for the result already, will head to the dyno in coming weeks to see where we are at.
09-10-2016, 10:10 AM
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atypicalguy Offline
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#61
RE: W124 dailydriver upgrade
Congratulations on that! Well done.

Are you ready to share the turbo sizes yet? I am in the same situation, chose my turbos and built everything but no idea of how well it will actually work! Leap of faith.
09-10-2016, 03:46 PM
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Sultzi Offline
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#62
RE: W124 dailydriver upgrade
Will let you know when I get this dynoed.

Made test run with 4gear from 80km/h to around 160-180km/h. Starting temperatures where 28 degrees c before laminovas and 20 degrees c after. They came up maximum at 100degrees c before laminovas and 40degrees c after. This at 3bar of boost.
09-18-2016, 03:47 AM
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Hario' Offline
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#63
RE: W124 dailydriver upgrade
Awesome! and 40degrees in the manifold wtf!

Here 'hp turbo has closening pressure coming from the hotpipe between turbos' Does this mean as drive pressure increases, WG will close and raise drive pressure more? Should it be other way round?

Beers, H.



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
09-20-2016, 02:08 AM
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Sultzi Offline
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#64
RE: W124 dailydriver upgrade
Still working on with the wastegates, but backpressure don't seem to be very big problem. With that hotpipe I did mean actually the pipe between lp turbo compressor and hp turbo compressor (aiming for around 1bar of boost at this pipe). But now I have just opening pressure for the lp turbo from the boost pipe between turbos and fitted with regulator. And hp has full boost opening and turbosmart boost tee from full boost to closing side of the gate. I think I would need two turbosmart boost tee's to make the adjusting more easier (that pressure regulator on the lp aint working so good than it should).

Today I was on the dyno to get paper for inspection. At this time we had time to tune the wastegates to 2,2bar of boost, original fuel filter and housing is showing to be too small, so need to update that too to get more fuel. But the result with 2,2bar was 407hp and 737nm at the wheels (around 450/830 at the flywheel).
09-21-2016, 01:21 PM
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erx Offline
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#65
RE: W124 dailydriver upgrade
I made 544hp/858nm from wheels with hx52 and 3.2 bar and with stock fuel filter, housing and fuel lines. It was smoking like crazy with 1.5bar pressure from 044 and 8mm 220cc so I had to reduce fuel from ALDA.
(This post was last modified: 09-21-2016, 02:19 PM by erx.)
09-21-2016, 02:11 PM
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Sultzi Offline
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#66
RE: W124 dailydriver upgrade
So here are the details for the turbos:
HP is MasterPower R545-2 (54mm compressor and 59mm turbine and 9cm2 housing)
LP is MasterPower MP6568 (65mm compressor, 68mm turbine and 1.05 ar housing)

Here is the dyno sheet, dyno starts to use brake from 3500rpm, so below that the dyno graph isn't showing the truth. At the road it has 0,1-0,2bar 2000rpm and 2500rpm -> full boost..
http://sultzi.kuvat.fi/kuvat/MB+300DT+-9...C_0324.JPG
09-24-2016, 03:49 AM
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Sultzi Offline
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#67
RE: W124 dailydriver upgrade
Finally did get those front bumper mounting points welded back together so got the bumper mounter too. Sleeper look now Smile
[Image: _medium.jpg]
[Image: _medium.jpg]

Backup engine also ready..
[Image: _medium.jpg]
10-03-2016, 11:41 AM
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maxypriest Offline
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Location: Norfolk, England
#68
RE: W124 dailydriver upgrade
That's making good torque before my hx40 set up does; Mission accomplished!
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
10-03-2016, 12:10 PM
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atypicalguy Offline
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#69
RE: W124 dailydriver upgrade
(10-03-2016, 01:11 PM)atypicalguy Wrote: What springs did you put in again? Km cams or from FRAS or?

Sorry for the double post. You already answered that question. 

DI'd laminovas come with mounting plates and tubes precut?
10-08-2016, 08:31 AM
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MFSuper90 Offline
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#70
RE: W124 dailydriver upgrade
Awesome project, looks like the laminovas are doing fairly well
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler Big Grin
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted         
10-09-2016, 08:02 AM
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Sultzi Offline
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#71
RE: W124 dailydriver upgrade
Laminovas are only just the cores, all other you need to fabricate yourself. But they do sell mounting plates and accessories too.
10-15-2016, 02:44 AM
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BoostedBenz Offline
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#72
RE: W124 dailydriver upgrade
i really like this build! the intake With the laminovas looks top notch!
89 Mercedes 190E Artic White  OM604STD Project
05 BMW X3 2.0D Sport
86 Mercedes 230E
14 Sea-doo GTR 215
11 Polaris 800 Rmk Assault
10-16-2016, 11:13 AM
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Sultzi Offline
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#73
RE: W124 dailydriver upgrade
Thanks Smile

Been now driving around 4000km, no problems, just a normal daily Smile

Updated the brakes, rear are 278x24mm and fronts 300x28mm and also r129 double brake booster.

[Image: _medium.jpg]
[Image: _medium.jpg]
[Image: _medium.jpg]
10-30-2016, 11:38 AM
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maxypriest Offline
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#74
RE: W124 dailydriver upgrade
What are those rear brakes from? Inc calliper?
Cheers
Max
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
10-30-2016, 01:20 PM
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atypicalguy Offline
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#75
RE: W124 dailydriver upgrade
(10-15-2016, 02:44 AM)Sultzi Wrote: Laminovas are only just the cores, all other you need to fabricate yourself. But they do sell mounting plates and accessories too.


I can handle the welding but I imagine the laminovas seal to the plates with o rings and that there are small grooves in the plate for those? I would not want to fabricate anything like that.

This is a great idea to save some space under the bumper.
10-31-2016, 06:18 AM
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Sultzi Offline
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#76
RE: W124 dailydriver upgrade
Rear brakes are from E420 and E500, calipers are from the same.

Part number for the disc is 124-423-08-12 and caliber 000-420-82/83-83

All these where just bolt ons.
(This post was last modified: 10-31-2016, 02:43 PM by Sultzi.)
10-31-2016, 02:43 PM
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atypicalguy Offline
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#77
RE: W124 dailydriver upgrade
(10-31-2016, 02:43 PM)Sultzi Wrote: Rear brakes are from E420 and E500, calipers are from the same.

Part number for the disc is 124-423-08-12 and caliber 000-420-82/83-83

All these where just bolt ons.

Do you have a number for the booster? Maybe it is the one in the photo. Thanks.
10-31-2016, 06:19 PM
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Sultzi Offline
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#78
RE: W124 dailydriver upgrade
Yeah, you can see it on the photo, there was some others that will fit too but don't remember those. But most likely all from r129 will fit? But atleast 300petrol has this bigger 1" and 3/4" master cylinder.

Car is now inspected and all modifications are written down too, now just needs driving and oil changes through the winter and maybe at the summer time I will update that fuel filter to better flowing one (already bought) so could get more boost and fuel Smile
11-12-2016, 04:17 AM
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hooblah Offline
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#79
RE: W124 dailydriver upgrade
Very nice. Looking forward to see how this progresses.
11-13-2016, 03:07 PM
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Sultzi Offline
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#80
RE: W124 dailydriver upgrade
Picture of the "finished" engine bay, nothing special. Did find enough room for the divider to get little bit cooler air for the filter..
[Image: _medium.jpg]
11-14-2016, 02:40 PM
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maxypriest Offline
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#81
RE: W124 dailydriver upgrade
(11-14-2016, 02:40 PM)Sultzi Wrote: Picture of the "finished" engine bay, nothing special. Did find enough room for the divider to get little bit cooler air for the filter..
[Image: _medium.jpg]

...'nothing special' my arse - its a brilliant build. Well done, looking fwd to some vid action and some dyno charts :-)
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
11-15-2016, 06:54 AM
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atypicalguy Offline
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#82
RE: W124 dailydriver upgrade
Nice work.
11-17-2016, 07:57 PM
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Sultzi Offline
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#83
RE: W124 dailydriver upgrade
Been mostly just driving, 10000km now with this setup.

Small vid before winter, just testing out setup..


02-07-2017, 11:14 AM
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Sultzi Offline
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#84
RE: W124 dailydriver upgrade
15000km now with this setup, now driving with 3bar in manual mode and when in automatic mode I have "only" 2bar. Still running with stock fuel filter, did find out that I wasnt at max fuel earlier with the screw on mekens pump, so no i have small haze when doing wot with 3bars. Could go to dyno just to be curious is there any change happened with the power Smile
05-11-2017, 10:26 AM
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Hario' Offline
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Posts: 896
Joined: Nov 2011
Location: SW London
#85
RE: W124 dailydriver upgrade
Awesome!!! Now what? haha



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
08-07-2017, 07:20 AM
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Sultzi Offline
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#86
RE: W124 dailydriver upgrade
This is for sale now, already have new car for daily driving Smile
08-09-2017, 04:15 AM
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Turbo Offline
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#87
RE: W124 dailydriver upgrade
so what is the new car...
08-13-2017, 02:45 AM
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Sultzi Offline
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#88
RE: W124 dailydriver upgrade
w210 e55 amg facelift, will be running with e85 mostly.
(This post was last modified: 08-13-2017, 03:33 AM by Sultzi.)
08-13-2017, 03:31 AM
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Turbo Offline
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#89
RE: W124 dailydriver upgrade
no diesel? how come this big change?
08-13-2017, 08:50 AM
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atypicalguy Offline
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#90
RE: W124 dailydriver upgrade
(08-13-2017, 03:31 AM)Sultzi Wrote: w210 e55 amg facelift, will be running with e85 mostly.

That is a nice motor. Had one in a gwagen for awhile. Great low end.
08-13-2017, 07:46 PM
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Sultzi Offline
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#91
RE: W124 dailydriver upgrade
Always like to try different things and see what they feel like, superturbo is good for daily driving that's for sure, but also v8 is nice with e85. Here they make e85 mostly out of waste (almost anything from vegetables to trees etc) and not purpose grown corn etc.

I always like to say that life is too short to drive boring cars and this also applies to drive same car more than 2-3 years Big Grin
(This post was last modified: 08-14-2017, 07:51 AM by Sultzi.)
08-14-2017, 07:50 AM
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Turbo Offline
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#92
RE: W124 dailydriver upgrade
(08-14-2017, 07:50 AM)Sultzi Wrote: Always like to try different things and see what they feel like, superturbo is good for daily driving that's for sure, but also v8 is nice with e85. Here they make e85 mostly out of waste (almost anything from vegetables to trees etc) and not purpose grown corn etc.

I always like to say that life is too short to drive boring cars and this also applies to drive same car more than 2-3 years Big Grin

It is always a matter of time before the the upgrade devil will come to visit again
08-14-2017, 01:55 PM
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Hario' Offline
C300TD Wagon (W202)
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Posts: 896
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Location: SW London
#93
RE: W124 dailydriver upgrade
4.0 v8 cdi after that? Wink



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
08-14-2017, 02:01 PM
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atypicalguy Offline
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Location: LA
#94
RE: W124 dailydriver upgrade
(10-30-2016, 01:20 PM)maxypriest Wrote: What are those rear brakes from? Inc calliper?
Cheers
Max

You can use the sl600 silver arrow rears (300mm) and you can use the later 500e fronts, which are 320mm. All of that bolts up. The rear backing plates need a bit of fine tuning with an adjustable wrench (bend the edges so the larger calipers will fit).

The first gen 500e calipers also fit, which are aluminum but only 300mm; this is the biggest that will fit under a 16" wheel. I run the first gens with the silver arrow rears; all 300mm. Works pretty well in the kombi. With a 500e master cylinder and an r129 booster. Good stuff.
06-17-2019, 11:05 PM
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atypicalguy Offline
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#95
RE: W124 dailydriver upgrade
(11-15-2016, 06:54 AM)maxypriest Wrote:
(11-14-2016, 02:40 PM)Sultzi Wrote: Picture of the "finished" engine bay, nothing special. Did find enough room for the divider to get little bit cooler air for the filter..
[Image: _medium.jpg]

...'nothing special' my arse - its a brilliant build. Well done, looking fwd to some vid action and some dyno charts :-)

Hey Sultzi I noticed that you did not do your turbo oil supply lines in steel, but you did all the wastegate stuff in steel. Do you really trust those braided lines more than you trust bent steel for a turbo oil supply? Thanks for any thoughts.
07-09-2019, 05:23 PM
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