my 940 aka 'the barge'

[MoleT-5R]

Nice build thread mate, thing's look to be coming along nicely I see. It may be a bit to late, but the temperature sensors you mentioned back at the beginning of your build thread, if your still looking for some Claymore was using some nice digital ones on his T5-k project, drop him a pm he'll probably be more than happy to point you in the right direction and I doubt that they would be to expensive, in fact they were probably a bargain knowing Colin

[AndysR]

Nice work, need to stop looking at the thread though as it's giving me ideas about modding mine... Lol

[artfulflounder]

Feel like i have to put a disclaimer in here now:

Please bare in mind this is my first time doing anything to do with porting or polishing, All work is carried out in a small brick shed come workshop.The tools i have are basic but they do what they're supposed to and all i've done is researched everything i could find to set me in the right direction.
I may be doing this completely wrong and don't mind you guys giving your input.
BUT i am going to gasket match the manifolds, turbo and clean up the head anyway, because i've never had the chance to before and if i do it properly then i'll be doing my 940 proud.

I started this knowing it could completely the car up. So don't copy me i don't know what i'm doing.

Started on the exhaust manifold tonight. Made a template and scribed the shape onto the manifold outlet.
As i'm fitting a 15g i made sure not to go too large so the template fell within the size of a ported hotside.

This is what i started with.

[IMG][/IMG]

Took some time to get used to it but progressed slowly. Just kept reminding myself you can always take more off but can't put it back. lots of ciggie breaks and checking.

[IMG][/IMG]

Still got some more time to spend on the shape/size but it started to get interesting. The shape of the runners became more pronounced and could start shaping those as well.

The cross shaped thing at the back is a 'goilet'. It assists in improving the merging of multiple flows into one flowstream.
It looks like theres some improvements to help redirect flow to the centre of the turbine inlet.
Will have a go at that tomorrow and post up the next set of pics.

Sorry if this is going to be a long winded project thread, but i learnt a few things i never knew and why not share.

[merc85]

looks good mate

[smithy]

That looks about right mate I bored a big hole in mine too .works well with a t4 on it .but next year I will be going tubular manifold .with that I should see 148bhp then .

[stribo]

That looks about right mate I bored a big hole in mine too .works well with a t4 on it .but next year I will be going tubular manifold .with that I should see 148bhp then .

What's that as whp?

[smithy]

What's that as whp?

No bhp
To make peeps happy lol

[artfulflounder]

After enlarging the manifold outlet the runners looked abit like this.

Sorry for the pics but its hard to get decent pics without blocking out the light, will pick up another lever arm lamp that should help.
Anyway.

[IMG][/IMG]

The runner exit is at a very shallow angle pointing straight across to the opposite runner. So i thought i would try to open the exit and try to redirect each cylinders flow towards the turbine inlet. I've flared the roof exit on each runner and widened them to a certain extent.

Again sorry for the pics:

[IMG][/IMG]

[IMG][/IMG]

My long shank carbide burrs and sanding cartridges didn't turn up before xmas unfortunately so i can't go any deeper than this today.

[wiganer31]

looking good mate, sounds like your doing similar to what i'm thinking so handy for me haha, picked up a 16t the a few weeks ago and the guy gave me some white injectors and a adj fpr so hopefully i can use them but not looked into proper yet

[artfulflounder]

The 16t will fit very well, oil and water lines fit straight up, just needs clocking for rwd, but you'll have to change the down pipe flange probably.
Think it will be flat or angled. A wide band 02 would be needed to keep tabs on your fueling.

Hurry up and start on ur head so i can learn by your mistakes.lol

[artfulflounder]

works well with a t4 on it .but next year I will be going tubular manifold .with that I should see 148bhp then .

Don't think I'll go further than the td04 series....supporting mods are more than I could justify and 19t will get high 200s which would do me fine eventually.
But if you do have a clear out then I'll be happy to accept charity.lol

[artfulflounder]

Still waiting for the long shank burr so had a go at the other end of the runners.

Used a new gasket to mark the manifold.

[IMG][/IMG]

[IMG][/IMG]

Tapered the runner so i could just see the outside of my marks then blended that in gradually. Ran over any seems i felt inside but again need the longer burr then running over with flapper and polishing.

[artfulflounder]

Got to the same stage with the other pair of runners tonight.
I've measured them and they all seem pretty much similar.

[IMG][/IMG]

[IMG][/IMG]

Quite happy with it so far,need to get in with a flapper and sanding rolls to smooth them out a bit more, half the knack is getting used to what the tool is doing.......glad i decided to do the manifold first.
Been continuing with my research......reading about exhaust reversion. whether its less relevant to a turbo and all that hu ha.
Basically if i do match the head then its better to be smaller on the exit port.

I don't always comment on peoples threads but been some good info on here recently.

M-R-P with his oil catch tank......i was actually researching this for the 940. Don't want to vent to atmosphere really. So i can can tap out the pcv seperator outlet and fit larger pipe with catch tank.
Tap a second smaller hose from the pcv so would have 2 outlets both to catch tank(15mm standard--12mm secondary)..... or some even tap into rocker cover for an extra feed( would have to be baffled).

Stribo with his downpipe and wideband boss fitment. Again something i'm looking at now so i know what i'm doing and have all the bits when i need them. As this also effects Woodys thread.

Woody T5 with his 3.8 bar fpr.....again something i'll need to sort. With a 15g and white injectors defo require more than 3bar.So i've found out what else i can fit. which is a bonus.

Anyone going to fit an adjustable frp.lol

All good info......cheers to all that contribute on the forum.

[merc85]

Looks like your doing a top job there buddy

Reminds me of when I did my t5's head

[artfulflounder]

Looks like your doing a top job there buddy

Reminds me of when I did my t5's head

cheers mate...

did you notice any change after you'd done it? Spool any faster, change power range.

[merc85]

seemed to rev free'er, not sure if it made much power difference but it boosted 2 psi more and was better on fuel picked up better to, but I did overhaul the head and skim it whilst it was all apart. deffo recommend doing it, I left the texture around the head of the valves and spark plugs in the combustion chamber, ive read that if you polish this area it can disturb the fuel/air mixture and make the car fuel badly as it doest atomise as well.

Also peeps cut the valve guides, I didn't do this either as I was doing it all by hand and had no means of doing so.

[smithy]

Nice work mate keep it going .

[graemewelch]

some very nice work there.

merc you got any more pics of your head. cylinderhead i mean

[Kingsford G]

Nice project there mate,the port-polishing going really well by the look of it.

[merc85]

some very nice work there.

merc you got any more pics of your head. cylinderhead i mean

yes bud what pics you want? here's a link I don't wana trash this thread doh

http://www.vpcuk.org/forums/showthre...855-t5-Project