Cavalier Turbo 4x4

[kread]

Some of you may regognise my other cav turbo

Kreads Cav Turbo
My Cav Turbo

well after much expense i ran out of funds and decided to put it in storage last october, during that time a took ownership of another cav

L401 TOY which was once owned by mark on vxon, then owned by a freind and is now in my ownership.

when mark had it


It then got rear ended, and written of cat d, damage was minor but as expected it was uneconomical repair, so i took on the shell stripped it and sold all the bits for its previous owner

its now looking a little sadder, although overtime it will be restored and retruned to its former glory although, slightly, upspecced!!!


taking the engine out for its new owner,


and the damage thats caused it to be in its current predicament





its barely moved the rear panel at all, maybe about an inch, and its twisted where the light is slighly at the bottom, but only a small amount so hopefully it'll all knock back out and then i just need to get a new rear bumper support bar and jobs a goodun!!

[kread]

Anhow, i have since knocked the boot back into shape and it now shuts and locks although still slightly out on the right side so a little more shaping is needed
with a rubber hammer and a block of wood,!!

the engine running gear from my grey one will work its way into this shell as overall its in better nick than the grey shell, i will then restor the grey shell

picked up my new block!!





iasa forged low comp pistons, steel rods, oil spray,

giving it a couple of coats of satin black hammerite, then i'll start building it up to mock up a new exhaust etc!

and transfer all the parts from the original engine!

[kread]

decided after reading so many good things about the td05 turbos from an evo, ive decided to sell my Garrett based manifold turbo and wastegate(thread in the forsale section) and fit a twinscroll manifold and td05,

picked up a td05 16g 10.5t from an evo8 but with the penny valve on the wastagate missing, for not much, gonna fit another hotside to solve the wastegate problem, and purchased a cheap tubular mani from ebay to weld the flange onto,

very surprised how close the runners and the ports on teh let head are to the evo ones, and the ones one the manifold are so much larger than the let ones, few issues with clearence to the dipstick breather tube to overcome but no great headache, learning to tig at the mo, so gonna tackle the manifld myself once ive had a bit more practice,

[Grim Reaper]

dude i love your grey tubby it looks so awesome

so if i skimmed this thread right, your now reshelling bits from the grey cav to another shell???

[Jay]

Subscribed,Good work keep it up m8

[leesturbo]

nice. the twin flappers are another restriction and should be avoided.
apologies on my part as i did not mention some evo turbo's have either twin or single flappers.
single flapper ftw
looks nice kread

[kread]

Subscribed,Good work keep it up m8

cheers, will be working a fair bit on it over the winter, ready fo r getting the car back on the road next spring

dude i love your grey tubby it looks so awesome

so if i skimmed this thread right, your now reshelling bits from the grey cav to another shell???

basiclly the rear offside of the grey shell is quite rotten, half the front of the arch is missing, and the paint work is shocking, however its not bad enough to stripp and scrap, plus i have 2 other let engines that although need a basic rebuild are useable,

the black TOY shell is in better condition and being slighly newer, less rust to deal with, paint works pretty good, bar a few swirls etc, so i will be stripping the black shell down, doing any welding that needs, then reundersealling better than it left the factory, powder coating the subframes etc and fitting new bushes etc etc, then fitting the drive train and big spec engine that i'm currently building,

the grey shell will then be stripped down, prob bareshell and taken back to metal repair work down and then resprayed, and built back up to more factory look, but still running around 250hp, with a cossie t3 etc, cant see the point of refitting kkk anymore,

then the other let engine i might build back up and stick in a corsa or something oldschool, chevette or sumin, who knows!!

[kread]

nice. the twin flappers are another restriction and should be avoided.
apologies on my part as i did not mention some evo turbo's have either twin or single flappers.
single flapper ftw
looks nice kread

when you say single and twin how do you mean, i'm guessing later turbos have twin flapper?

karl

[leesturbo]

you could cut this lug off to the left of the yellow line as you won't need it
becareful to not cut to close to the diffuser and making a hole

becareful to not cut to close to the diffuser and making a hole
then that will give you enough room to get a plate on the dipstick hole to fabricate breath/dip stick holder

[leesturbo]

when you say single and twin how do you mean, i'm guessing later turbos have twin flapper?

karl

no earlier turbo's have twin flappers

[kread]

yeah, speaking to stupink i cut away some of the housing for clearence so looks like thats the plan, plus the way i'm gonna weld the head flange on i'll be spaceing it out buy 13mm also,

so ideally i need a late hotside, which evo? 8 onwards?

karl

[oli_p]

will be keeping an eye on this want to know how it goes before i fit one to mine, wouldnt it be easier to have the turbo facing the other way round turn it 180 deg, maybe have abit extra room then??

[kread]

prob not, i dont think the flange is semetrical the other way, dont think the space will be a massive problem, once ive spaced it out slightly

[Adam]

subscribed

[oli_p]

would say cut flange maybe then re-weld it back on but would probably make it even more hassle

[kread]

yep and got to sort out the seperated ports etc, be much easier when the head flange is welded on and i can space it out slightly, plus i can grind away some of the housing, plus i'm prob gonna go for a smoothed engine bay decluttered, and batterys in the boot now so can make more use of that side also

[leesturbo]

exhaust down pipe is easier to fab with nice smooth bends having it that way.
you can easily extend the airflow plug/wires so your intake will be around the battery area

[mikegray]

Subscribed, glad to see some more Cav T's being saved

[kread]

exhaust down pipe is easier to fab with nice smooth bends having it that way.
you can easily extend the airflow plug/wires so your intake will be around the battery area

ive already extended the loom as i had the t04e i had, and does make the downpipe much easier

[leesturbo]

ive already extended the loom as i had the t04e i had, and does make the downpipe much easier

[fromthearth]

great thread. ill be keeping an eye on this one! i can see a lot of people going down the tdo5/6 route after reading the thread in the engine/transmission section.

any gen on extending afm wires? i think i read on here it wasn't just a simple case of extending the wires?

[kread]

great thread. ill be keeping an eye on this one! i can see a lot of people going down the tdo5/6 route after reading the thread in the engine/transmission section.

any gen on extending afm wires? i think i read on here it wasn't just a simple case of extending the wires?

yeah could be a better conversion than the usual t43 stuff, i just extended my loom using some cable a mate had from his job, seemed to work fine, to be honest i'm gonna be going custom managment eventually so not so fussed in the long term

[kread]

bit of an update, compered the 2 head gaskets,




the ports are very close, and the bottom 3 bolts almost line up perfectly, due to needing some spacing away from the head, i;m gonna weld the let flange straight to the evo one,

[oli_p]

looks like good idea, what thickness LET flange are you going for??

[leesturbo]

should be ok kread all you have to do then is say drill the bolt holes thru at 10mm to get the 8mm bolts thru that are just off and get a decent washer on it.
yeah the ports on the evo head are big