Project Brento-Box

[brentonodon]

Ok party people. It's been forever. I'm not dead, the project isn't dead, there have just been some other fun things going on like a bike build and a boat trip. But back into it. A few months back I was able to get the turbo on. Sourced a turbo with exhaust manifold and bypass valve from fleabay. That's now been mounted up and a new intake installed thanks to the spleandors of ebay as well. It's running but still needs intake and exhaust finished up. To swap out the fuel pump I had bought a turbo version of the fuel pump with the boost comp setup but upon cracking it open found it was really gunked up and would take a lot to rebuild. Instead I took the fuel metering setup off the new pump and installed it on the old pump. I'll lose some of the functionality but it still works just fine. I'll get some pics up soon. Though it's looking like my old pics are all jacked up. What's up with that? Too inactive of a thread?

 

[brentonodon]

The original naturally aspirated setup I had on the motor. Had a great, high flow looking intake. but it wouldn't allow for the turbo to fit so it got the axe.


Then here's the difference on the fuel pumps. The one on the left is the turbo which has the diaphragm to allow for more fuel under boost. The main internal difference on these is the link between where throttle cable connects to the fuel metering lever that controls the amount of fuel pump pump.


The old one, seen here is just a spring.



The turbo version is a bit more "advanced". With a little finagling I got the old spring style to work on the new, turbo housing. There's a little spacer to keep it in the right location.



So far it's working just fine. We'll see what happens under heavy load.

 

[brentonodon]

Here's some pics of the turbo installed. Need to clean up plumbing and all that jazz.


The one other mod I had to take are of was the oil filter mount which houses the oil pressure gauge and more critically for this, the turbo oil return hose. Turns out that feature is cast into the housing but not machined and the fitting isn't installed. So I machined the bore out and machined up a nipple for it that I pressed in.


I'd love to replace those barbs with some AN fittings or something. In due time.

 

[brentonodon]

Massive post dump. On top of all that I've been working on the airbox and exhaust. Decided to weld up a filter housing that will bring in the air from the snorkel to a donaldson filter.



Still need to make the cover, install the riv-nuts, add a duck-bill valve for draining, and some mount brackets but it's getting close.



The exhaust is honestly a bit ridiculous. I've squeezed in a 3in stainless setup with a flowmaster muffler. It also needs the finishing touches still (brackets, tailpipe, flex section, and adapter to the downpipe. Quite a bit bigger than the stock gas setup which I think was like 1.75"

 

[brentonodon]

Well today was some good progress. Made 2" to 3" adapting section along with the spherical interface for the turbo downpipe. Also got in some final welding on the muffler section.

This was the idea going into today. I needed to adapt from the 2" outlet of the turbo hardware up to the ludicrous 3" sections. Then an elbow, and a flex section. Luckily we had an old stainless velocity stack kicking around that I turned into the size adapter so that was simple.



The big challenge was this kooky spherical seal that Mitsubishi used. I wanted it to bold right up to the old turbo dump so on to the lathe we go.


the flange and size adapter and seal all get assembled. I really wanted to make a fresh shiny flange but didn't have the plate laying around. So old carbon steel it is.


Here's the whole downpipe assembly. Looks alright to me and fits like a glove.


Next time in the shed I'll be making the hangers and bracketry. Till then I've got all the measurements I want for the muffler mount bracket that will use the stock rubber mounts. Should be fun.

 

[Toasty]

Excellent work!

 

[brentonodon]

Last night was a late one. Got the muffler mount sorted. One downside is I've got to remove the torsion bar to remove/install but that's not a hard go. Really wish I had a lift so it would be easier to get a shot of the whole thing. Only bits left now are the actual tailpipe and it's hanger. Then the serious clamps.



Link to a video of the layout. Trying to add in videos on youtube to help keep track of what I've done on here.

 

[brentonodon]

Good day in the shed yesterday. Lots done. The exhaust is now done. I also swapped the OME heavy duty torsion bars out for the stock ones. I'll be doodling up and printing a set of those upper bump stops somedays soon so I can get a little more range on the front. Also made up a little replacement wheel well intake port to accept the 3" intake plumbing and welded on some bracketry for the airbox. LONG day.

 

[brentonodon]

Well there’s nothing like having to use the project truck to get home because you forgot you rode the bicycle to the shed and missed the ferry back across the bay to get you to finish up the project quick. Made a lunch stop at oreilly and got some hoses, clamps, and a hose adapter for the vent hose. Then got her all buttoned up and did the maiden voyage. Holy smokes that’s a difference!!! Now I’m not saying it’s fast by any stretch of the imagination, but before i could barely keep 60mph when crossing the bay bridge here. Now, with the intake, exhaust, fuel pump, and turbo i can actually accelerate at 65 up a hill in 5th. Currently rocking about 10psi of boost according to my earlier tests but I’ll need to add in a boost gauge along with an EGT gauge. Soon enough. For now I’m pumped. It drove great and feels like a huge accomplishment. Good day.

Here’s the last pic of the Airbox with the polycarbonate cover, bolt ring, gasket, and rivnuts all installed.

 

[brentonodon]

Well now we're in a bit of a pickle. Driving around yesterday I noticed that in third if I give it a bit of gusto I can hear what I believe is the clutch begin to slip. I hear revs go up but not accelerating at the same pace.................womp womp. Might be time for a new clutch. Anyone got a preferred source for a clutch?