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  1. #2201
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    Again with COVID and time passing away - my thoughts on where I am going next. There is boost creep. I originally thought the SBC was playing up so at some expense I replaced the twin solenoid controller. Makes no difference. Boost is uncontrolled above 5K and peaks out around 1.7 bar. Thankfully the engine appears strong enough to take it.

    I still have an AFR bung to fit. My main thoughts now are towards boost control. I don't think I want to change the exhaust manifold - not after all that work and money, to fit something with an external w/g fitting. e.g. http://swedenexhaust.se/en/volvo/198...rial-mildsteel plus I am not sure this would clear the brake booster on a LHD car. TBH boost creep was never an issue I'd thought I'd have to face. I can either port the W/G hole further and increase the flapper size? or fit an intercept between the manifold and the gtx, with some kind of v-band flange or feed pipe to an external w/g.
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  2. #2202
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    MoleT-5R's Avatar
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    Quote Originally Posted by Wobbly Dave View Post
    Again with COVID and time passing away - my thoughts on where I am going next. There is boost creep. I originally thought the SBC was playing up so at some expense I replaced the twin solenoid controller. Makes no difference. Boost is uncontrolled above 5K and peaks out around 1.7 bar. Thankfully the engine appears strong enough to take it.

    I still have an AFR bung to fit. My main thoughts now are towards boost control. I don't think I want to change the exhaust manifold - not after all that work and money, to fit something with an external w/g fitting. e.g. http://swedenexhaust.se/en/volvo/198...rial-mildsteel plus I am not sure this would clear the brake booster on a LHD car. TBH boost creep was never an issue I'd thought I'd have to face. I can either port the W/G hole further and increase the flapper size? or fit an intercept between the manifold and the gtx, with some kind of v-band flange or feed pipe to an external w/g.
    I'm assuming that you think the wastegate is not allowing enough exhaust gases to by-pass the turbine, thus boost creeps up uncontrolled, is the the wastegate actually opening fully under pressure conditions ?? is the start point of the wastegate set correctly and is it sprung correctly for your application ?? finally if you back off the wastegate set load at rest, does this improve/reduce the boost creep or make it worse, or even have no effect at all ?? Worth having a play with the wastegate with a mittyvac and seeing how it's operating and open. Also playing with the setting on the rod may help (reducing it's load at rest), as it costs nothing but a bit of time in the grand scale of things and may help point you in the right direction or even possibly even solve the issue. Good luck Dave hope you find these ideas useful.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  3. #2203
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    Quote Originally Posted by MoleT-5R View Post
    I'm assuming that you think the wastegate is not allowing enough exhaust gases to by-pass the turbine, thus boost creeps up uncontrolled, is the the wastegate actually opening fully under pressure conditions ?? is the start point of the wastegate set correctly and is it sprung correctly for your application ?? finally if you back off the wastegate set load at rest, does this improve/reduce the boost creep or make it worse, or even have no effect at all ?? Worth having a play with the wastegate with a mittyvac and seeing how it's operating and open. Also playing with the setting on the rod may help (reducing it's load at rest), as it costs nothing but a bit of time in the grand scale of things and may help point you in the right direction or even possibly even solve the issue. Good luck Dave hope you find these ideas useful.
    I have tested the car with the wastegate flap wired fully open to prove the boost creep, which is self evident. I have played around with different settings and used the mittyvac I bought recently to ensure that the SBC was working properly (generating a false pressure into the SBC solenoid to check that it is releasing the boost) and to ensure that the pretention on the W/g actuator was correct. I definitely have boost creep, because above 5K even with the flapper wired fully open it made over 1.5 bar boost.
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  4. #2204
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    Quote Originally Posted by Wobbly Dave View Post
    I have tested the car with the wastegate flap wired fully open to prove the boost creep, which is self evident. I have played around with different settings and used the mittyvac I bought recently to ensure that the SBC was working properly (generating a false pressure into the SBC solenoid to check that it is releasing the boost) and to ensure that the pretention on the W/g actuator was correct. I definitely have boost creep, because above 5K even with the flapper wired fully open it made over 1.5 bar boost.
    It would seem that the wastegate is under spec for your application as it's still driving the turbine to give 1.5 bar of boost even when fully open, is there a larger option one for your turbo?? as it seems a bit undersize compared to the turbine housing in one of your earlier pics in your thread.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  5. #2205
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    Scrub that as I've just been further back in your thread and can clearly see the hole is in the GTX turbine housing and not on the wastegate as I had assumed, that said it does seem a very small hole for all those gases to by-pass the turbine when your hard on the loud pedal and the wastegate is trying to control the boost, could the hole diameter be increased to give a bit more control when the flap is open, just a thought....

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  6. #2206
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    Ade - I looked at these and this also was my first reaction. For a kick off the zircotec coating has been set into the hole. So my plan now is to remove the GTX and see how much the hole can be increased without replacing the flapper and clear out the blue ££££ out of the hole.
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  7. #2207
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    That hole looks smaller than a factory TD04HL turbo wastegate.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
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  8. #2208
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    Quote Originally Posted by Dangerous Dave View Post
    That hole looks smaller than a factory TD04HL turbo wastegate.
    It does look tiny for such a large turbo tbh.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  9. #2209
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    How was this build so far? Its been weeks since the last upgrade.

  10. #2210
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    Been years more like. I am in the process of moving house. The turbo needs to come off. And I can't really do this until after the house move. Betsy is going to stay with my FIL in Wales very soon.

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  11. #2211
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    Been years more like. I am in the process of moving house. The turbo needs to come off. And I can't really do this until after the house move. Betsy is going to stay with my FIL in Wales very soon.

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  12. #2212
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    Volvos never die - they just live off old ones.
    I used the opportunity to have some long overdue paintwork done on Betsy. Windscreen has been removed to sort the rust around the apperture particularly at the top n/s corner of the A pillar. Also the massive wart of rust pushing through the ns rear quarter has been sorted. I got hold of a donor quarter from someone breaking a C70 coupe. I sent him some spot weld drilling tools and he got me most of the quarter. My repair shop guy in Telford took what he needed from the donor panel to essentially replace most of area under the crease line. I've also had the bonnet and rear bumper redone for cosmetic damage, so she'll look like a new car when I get her back.Name:  244750042_10159709604367328_2972972020906139355_n.jpg
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  14. #2213
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    Ah she'll look lovely. That's one of the things on the list for my green beast, respray.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
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  15. #2214
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    As above, she'll look lovely..... especially flying through the highlands and also as above I need a respray to, but on Gul.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  16. #2215
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    Picking Betsy up with new MOT and paint job from the body shop end of this week. Really looking forward to it. Once I've got her to Jedburgh - I can start trying to remediate the overboost and hopefully find a final remap to suit. I just don't think I have the budget for stand alone.
    Last edited by Wobbly Dave; Sunday 27th February 2022 at 22:05.
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  18. #2216
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    Nice one Dave, will be nice to see it on the road again.

    I was around your old haunt Telford today at Newdale Primary.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
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    2004 Sapphire Black S60 D5 - The new daily hack.

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  20. #2217
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    You thinking of using Vast for your tune Dave ?, I think that's who jimbob used, afaik they have good reputation.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  21. #2218
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    The new actuator bracket has been painted and fitted now and the port on the W/G opened out to as much as possible. I've had the bung welded in to the downpipe and redone the wrap and painted it in cool-tec bronze.
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  23. #2219
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    How much bigger is the wastegate hole now, to how it was originally Dave, if you don't mind me asking, do you have a before and after measurement....?

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
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  24. #2220
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    Quote Originally Posted by MoleT-5R View Post
    How much bigger is the wastegate hole now, to how it was originally Dave, if you don't mind me asking, do you have a before and after measurement....?
    I fenced the work out to someone else. I only noted the fact that by the hinge side there was a few mm of meat left that could be taken away. I have been assured that it will do the business.
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