Project: Mavro Gato - 99 Turbo'd 3L

[fordrule]

update

[FastCougar]

I pulled the oil pan, removed the windage tray & oil pickup and removed the valve covers today ... preparing to tap the block for the turbo oil return line. I don't have the parts for the oil supply to/from the turbo, so I had to order them as well ... Once the oil return line is tapped into the block, I will begin final assembly and drop the lump into the Cougar

I should have an update in about a week or two. Slow going right now, waiting on parts. I got a little ahead of myself and basically spent a few hours today back tracking.

Here is a picture of what I'm talking about doing (tapping the block vs. tapping the pan). These are from the rolled Contour's engine that was recently sold & installed in SVT3391's (Rick's) SVT Contour:



Why I decided to tap the block vs. the pan:

Level pan with not quite 5 qts of oil in it (around 4.75 qts.)





6 quarts will no doubt raise the static oil level well above the pan's mating surface.

[bensenvill]

question since your waiting on parts. I loved your whole build thread on CEG of the tour, all the details of each step really brought to life the whole build process... but heres where I'm an idiot on, where and what did you order for the turbo oil lines. I'd really like to see one step of "I ordered these parts [for the oil line], I expect it to snap together like this, and finally well it all basically went together but I overlooked this and needed this tool to refab something".

[FastCougar]

Quick update ... the ATP turbo oil supply line/fittings and return oil line/fittings will be delivered tomorrow. I should have some progress to report on Tuesday/Wednesday night.

[FastCougar]

Well, everything came in the other day, but just found the time yesterday to tap the block and reassemble, but didn't have time to download and post pictures until tonight.

















Now for the interesting part ... 70mm TB (70mm before throttle plate, flares to 72mm where it mates to the flange). So, quite a bit of porting must be done. The red outline is the 65mm TB gasket outline. Here I'm removing the "nubs" aft of the EGR path outlets.



"nubs" removed, now widening the bore.



boring complete.



Here is where it gets interesting ... It still needs about 5-6mm more removed, but this will interfere with the EGR path and I don't want to pressurize the EGR passage, so it's time to get creative!



Here you can see the EGR passage exposed on the outside of the TB ... what to do ...



The "spacer" gasket that Warmonger supplied with the TB shows that it will cover the passage just fine ... I plan on using a gasket, then this plate.



Even then, the TB has a built in passage that needs to be blocked off ... this picture illustrates the massive leak that would exist if it's not blocked off.



Some "QuickSteel" will solve that.



And it's what I'm using to block off the EGR passage (for the time being while I port out the bore to 72mm. This picture shows the guides I penned with the TB attached.



The plan is to "flare" the bore so that incoming air doesn't hit a flat surface face on ... horrible for flow. I then plan on using a router bit on my dremel to channel out the EGR passage.

[Instigator]

so that was where that leak was coming from (the 2nd one next to the TPS)

[FastCougar]

Update: You guys know me ... never one to cut corners. I ended up routing out all the QuickSteel ... better safe than sorry! That would suck if a chunk broke off ... there goes a $4,500+ engine

I don't have any pictures to post, but I ended up making my own gasket for the TB and it came out awesome (gotta have the right tools ... in this case, a gasket punch set). I'm going to use that as a template for making my own metal seperator. Not that Tom's didn't work, but I need it to cover the gaps that boring exposed. The pictures that I post when I'm done with the UIM will speak volumes.

[drummerboy827]

It's always nice to have piece of mind over stuff like that too. If I eever "ghetto rig" something in my car, and I hear a strang noise or something doesnt feel right, I always think about the piece I half a$$ed first.

On another note, I've been watching motor builds on here occur for a few years now, and I have to say your's is the nicest i've seen yet. For whatever that's worth. Keep up the good work.

[FastCougar]

Well, I will explain a little, but the pictures do most of the talking ... pretty self-explanatory

I began by routing out QuickSteel after talking to Warmonger ... It was a hasty decision on my part to begin. I also cut in some galleys for the air to flow pas the areas where the EGR passage meets the incoming air.



closeup of the routing & air passages past the EGR outlets



Why the old metal gasket/separator couldn't be used ... this gasket that I made is extremely similar and shows how the incoming air will meet many obstructions



So, I decided to mark where I should leave "tangs" in order to fold them over and used this gasket as a template for a new metal gasket/separator



The resulting metal gasket/separator (before de-burring)



And why I went through all the trouble ... actually, it wasn't much trouble or that hard, but required me to buy some new tools (way overdue)











Now I just need to finish removing all the casting flash from the outside of the UIM and then it's time to polish it ... more to come tomorrow night

[Blackcoog]

Nice job. Looks like it will work out perfectly.