Max Hughes

Holset HY35
Dodge ram down pipe mount
Some 97 e320 manifolds to fabricate into a single turbo manifold, theres no room in the rear for a remote setup so scratch that.
extra 97 e320 recirculator valve

dgiturbo

A long long long time ago I used fabricate and build turbo kits for naturally aspirated cars. I like your project idea, if you need any info let me know. By the way, what are your plans for fuel and engine management?

Max Hughes

SAFC NEO for the fuel along with a 5 bar fpr and 310cc injectors(#30), regulator and injectors are uninstalled but the NEO is installed so i could calibrate it.
I might use a DIS 4 if i need to dial the ignition back or i could just get a higher voltage r16 resistor to take the timing back a few more degrees.

If it turns out to be too many different systems ill switch to a single AEM ignition/fuel piggyback unit.

Im flipping the manifolds and fabing a Y-pipe, but i would like to find a e320 exhaust and hack the manifold to exhaust pipe connections so i dont have to make those cause that would take forever.

Really the hardest thing is making sure they are spaced correctly because i have to drive the car everyday so i cant fab the mani on the car. I have to measure the gap between the two manifolds and tack them together temporarily so i dont fab up a mani thats completey off.

dgiturbo

Stand alone is a good way. Can't remember if AEM makes one for the MB. The E class air flow sensors are notorious in stock use, so be careful with a turbo. The air being pulled through may overload it. Help me out, what is NEO?
To make the manifolds, see if you can by a one piece exhaust gasket to use as a template. Just make the bolt holes a little bigger to get some wiggle room during install.
How much boost? What are your expected hp gains?

Max Hughes

- Its my daily driver and i want to keep it simple so i like to use piggyback units.
-AEM makes a universal piggyback that i have installed a couple times for friends in 2 BMWs and 1 honda. AEM Fuel/Ignition Controller is its name. They arent car specific but if i wanted i could hardwire it to my car in an hour or two.
-I think the MAF will be fine up to 400 at the crank. There is a supercharged M104 with 400 at the crank running a blow thru setup on the maf.
-The SAFC NEO is a fuel controller, its the newest one from Apexi. It makes very noticable adjustments to the fuel system, if you want you could go up to 50% more fuel delievery, and works great.

Quadcammer

I think you will regret doing this on your daily driver.

Max Hughes

Eh im the stereotypical teenage gearhead minus the rice factor so many of my buddies like. Im keeping this car simple on the outside and the interior, all the action is in the engine bay and in the drive train.

Anyway heres what 3 hours of handsawing got me. Half way to making the turbo manifold It took that long cuase i had to start from the top so i could cut all 3 without getting the blade binded.

Max Hughes

And also an exhaust and of course it was FO' FREE! Im useing the ends of it so i dont have to weld directly to the manifold

Max Hughes

This is acutally done, gotta wait till dad gets back with the sd card. Heres one pic i did have though, this is a couple days ago when it was cut to size for a log style manifold.

Yacht Master

Max,
What process do you use to weld to the cast iron?
I am sure you have seen this,
https://mbworld.org/forums/showthrea...hlight=pumpish

Max Hughes

Its schedule 40 steel not iron, i mig tacked it real fast and tig'ed it. Heres one more pic i had of the mock up.


Roman owns his own tuning shop for mercedes and other cars so he would have those resources, i have a mig, a tig, and a band saw.

Yacht Master

[QUOTE=Max Hughes;2762228]Its schedule 40 steel not iron, i mig tacked it real fast and tig'ed it.QUOTE]

I must be missing something here Why did you cut the Cast manifolds?

I thought you were using them for the new turbo manifold. By welding the schedule 40 steel to them.

Max Hughes

Theres no way its cast, theres milling marks on the back of the flanges and its obvious the manifolds were made in a two step process. The pipes were formed out either by water, air, or a press. The flanges were cut out and then the pipes were welded into the flanges. If i had some high quality you'd see what im talking about. It welded fine and is strong as hell with the 35 pound turbo hanging off of it.

Max Hughes

Heres some progress on the redesign. I got a better turbo but it didnt fit like the old one so i remade the manifold and am redoing the drain and adding an intercooler.


This thing is way easier to get out than i expected. Seriously, i dont even have an engine lift, i used 2 car jacks and couple blocks of wood.

Hirnbeiss

Great project , Max, keep us posted.

michakaveli

For th eintercooler you could probably use the mounting brackets and intercooler from a 98-99 E300 Turbodiesel. They are mounted in the same area that you have that one hanging

Max Hughes

I could never find the td intercooler, only the ml diesel and c class intercoolers.

Heres some progress, i got a real engine lift this time and a new pan gasket. Oil pan is delayed till tommorrow, hopefully the manifold isnt delayed.

ohlord

m104 a bit over 300 hp low boost,no need to change pistons.
http://www.mercedesforum.com/m_39412..._1/key_/tm.htm
a few other company's made them so some digging on engine management turbo m104 may pull up some good info for you.
Looks like nice work so far,and will run far better then the old proposed remote unit
ohlord
"GOT BOOST?"

Red66GT

Subscribing. Nice work!

Tommy_s4

Good work and keep it up, your doing what i had wanted to do.

HOWSER

I thought you did?

Ozcan

Max Hughes the more I look at the pictures you posted the more I am convinced that you will be successful. Keep up the good work.

michakaveli

+1.... Looks like someone that has a solid game plan at making this work!

Max Hughes

Max Hughes

Heres how i had to remove the oil pan a second time lol guess how it came out? I had this spare in there so i could move the car.