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Old 28th March 2013, 19:16   #46
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Default Re: Building a G16b - Turbocharged + ITBs

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Query no. 3: which engine oil is planned? An off-the-shell synthetic or some witch's brew/snake oil?!
Any off the shelf fully synthetic oil will do. You don't need snake oil.
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Old 29th March 2013, 10:33   #47
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by Rehaan View Post
Am following this build keenly!



Video please



Given that this is not a sequential box, how will you be doing this?

Will the gear lever knob have a sensor on it like a regular flat shift system? Or will you just use the clutch sensor and take a guess at the revv-matching based on whether its above or below certain RPM thresholds?

Do you think you'll be able to shift without the clutch, or is this only a way for you to keep the boost high and match revvs better?
Since this package does not have a dedicated up/down sensor on the gear lever as in the case of a sequential shifter and the fact that the engine does not have a drive-by-wire throttle system, the clutch senor is used to limit revs when up-shifting.

Clutch is required for shifting on this helical gearbox, you are right about holding boost and rev matching.

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Does the Baleno know which gear it is in, or will your guys need to add a sensor for that?

I guess cars today (eg. Vento) have upshift indicators built in - so they would have this info.



Cool
The ECU takes into account vehicle speed and Engine RPM ( considering clutch slip is within limits ) the ratio of engine RPM to vehicle speed is different for each gear but almost constant for a given gear, using which current gear can be identified.

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Thats a lot of info for an instrument cluster! Since i know Karthik probably writes the code himself, it would be cool if you could press a button to switch to a cleaner display screen - where only the key pieces of info for driving are displayed.

cya
R
The screen here is over 2 years old, and the dev team had incorporated 2 flippable screens layouts. Newer version will probably have more layouts with a touch screen interface.
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Old 29th March 2013, 18:56   #48
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by Racedynamics View Post
The screen here is over 2 years old, and the dev team had incorporated 2 flippable screens layouts. Newer version will probably have more layouts with a touch screen interface.
Boss: No touch please Not on a car!!!!

Imagine a scene where the driver uses gloves, then touch becomes funny to use..
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Old 29th March 2013, 20:48   #49
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Default Re: Building a G16b - Turbocharged + ITBs

Thanks for the post karthik

Quick Update: Engine is in, faced a number of setbacks which ensured the car could not be started today.

Oil feed banjo bolt was one size too small.
Crimp on the battery ground cable had broken.
New Hoses for the itbs were longer and had to be shortened
All the T-bolt clamps were a couple of mm shorter than the advertised size - Will source and use regular clamps for the run in until the new t-bolt clamps arrive
The slimmer radiator fan is yet to arrive.

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Boss: No touch please Not on a car!!!!

Imagine a scene where the driver uses gloves, then touch becomes funny to use..
This is a daily drive car - and there will be multiple screens to ensure only the required info is displayed as per requirement - one layout for street, one for track etc
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Old 29th March 2013, 21:52   #50
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With regards to oil, will break in on mineral and shift to synthetic later on. Looking at hks, indemitsu or Wurth. Lots of equally good stuff available (motul, ows, mobile1) but I get much better rates on the first three so will stick with them.

Everything mounted
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Old 29th March 2013, 21:59   #51
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by vikram_d View Post
Any off the shelf fully synthetic oil will do. You don't need snake oil.
Hadnt you used some of that snake oil in your turbo build ?!



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Oil feed banjo bolt was one size too small.
Hope no damage to the turbocharger. Was the engine cranked/how long was the engine running before discovering this?

Last edited by theMAG : 29th March 2013 at 22:01.
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Old 29th March 2013, 22:23   #52
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Default Re: Building a G16b - Turbocharged + ITBs

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Hope no damage to the turbocharger. Was the engine cranked/how long was the engine running before discovering this?
Engine wasn't anywhere close to being cranked. It was while checking to see if the bolt fits(considering this oil restrictor is specifically for the TD05) that it was found to be too small. The oil line wasn't even being connected when this happened.

There are a lot of checks that happen well before the car is cranked for the first time so absolutely no worries there.
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Old 29th March 2013, 23:38   #53
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Default Re: Building a G16b - Turbocharged + ITBs

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Hadnt you used some of that snake oil in your turbo build ?!
The only snake oil I used was called Castrol Magnatec with so called synthetic technology and it never let me down and this includes my Leh trip.

Disclaimer: My build was only running 8 psi and it was a daily drive build.

Last edited by vikram_d : 29th March 2013 at 23:40.
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Old 30th March 2013, 10:47   #54
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by headers View Post
Boss: No touch please Not on a car!!!!

Imagine a scene where the driver uses gloves, then touch becomes funny to use..
For the same reason its a resistive touch interface .
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Old 1st April 2013, 15:08   #55
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Quick update :

Almost everything is in except the oil feed line for the turbo. Hopefully once that is done the engine can be cranked for the very first time.

After going through a bunch of radiator fans at the godown of jk automobiles, settled on a slimmer a/c fan and housing from an Ohc type 1. New mounts were fabricated for it to bolt onto the oe radiator and it sits perfectly.

Also picked up a set of new headlights, the front end looks a lot better now!

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Old 2nd April 2013, 19:27   #56
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Default Re: Building a G16b - Turbocharged + ITBs

Excellent build. Looking forward to seeing the car in action. Can I drop by at RD for a bit of a look see?
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Old 2nd April 2013, 21:33   #57
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Owning to the design of the exhaust manifold, the radiator plumbing had to be fabricated from scratch including a mount for the stock coolant temperature sensor. While it was fabricated earlier, a large part of the day went towards getting it to fit perfectly, ensuring the sensor mounted like it should. This was completely wrapped with heat wrap before being installed. The intercooler plumbing was also welded up to reduce the number of hoses - which tend to be points of failure. Picked up an fpr from v1p3rs place which leaves only the turbo oil feed to be done.

Tomorrow looks promising!


Quote:
Originally Posted by amarpreet99 View Post
Excellent build. Looking forward to seeing the car in action. Can I drop by at RD for a bit of a look see?
Sure .. You are most welcome to come by!

Last edited by binz : 2nd April 2013 at 21:44.
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Old 2nd April 2013, 21:47   #58
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by binz View Post
..settled on a slimmer a/c fan and housing from an Ohc type 1.

Hope this fan will support sufficient air flow volumetrics etc. required for this build.

Also, when can I get that test-ride after the build settling down ?!

Last edited by theMAG : 2nd April 2013 at 21:49.
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Old 2nd April 2013, 23:57   #59
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Default Re: Building a G16b - Turbocharged + ITBs

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Hope this fan will support sufficient air flow volumetrics etc. required for this build.

Also, when can I get that test-ride after the build settling down ?!
Since the fan is required only at low rpm/idle conditions this will do the job perfectly. Already have a fan controller which can be programmed to turn on the fan from as low as 70 Degrees(Fan is set to turn on at 90degrees on the baleno from the factory) so no issues there.

Hopefully at the end of the month - once run in is done and the cam is in
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Old 3rd April 2013, 18:13   #60
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Attempting to start the car now!

And she runs!! Started on the second crank and sounds amazing - Never seen a turbo car pick up revs so quick. Karthik got the car to rev at 800rpm within a couple of minutes, and I can wait to see him tune this on the road.

Pictures and a video will follow, this build has blown away everyones expectations so far. Hope everything holds up well from now!

Last edited by Rehaan : 4th April 2013 at 16:43. Reason: Merging posts now. Looking forward to videos!
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