UPDATE 10/8/132/28/14 on Page 7 - almost done with the pie cut manifold!
have a sneak peak.




UPDATE 10/8/13 on Page 2 - Light bar bracket fabrication part A and bosch water pump for intercooler mounted behind drivers crush tube
UPDATE 10/4/13 on PAGE 2 - Garret Heat exchanger arrived today! Already cut off the standard fittings and welded new ones on!
UPDATE: 8/27/13 on PAGE 2 - minor interior "mod" and updated upper engine mount to post-facelift version to gain more room

Hello everyone,
I will be using this thread to post photos and updates of my impending build.
This may be a little slower than normal as I am currently mainly focused on building an apartment, getting settled as project lead on a few different development projects at my new job, as well as other shenanigans and social life activities.

End goal is a fully unique twincharge mini that is fully flex-fuel (No map switching, using 4d and 5d fueling and timing tables) (I know cons of twincharge vs either or, but I want both) I am doing the twincharge in a way that has not yet been attempted (turbo post throttle body with the bypass valve dumping pre-turbo)

I have re-worked the engine bay layout to make some more room, as well as I am currently running a ViPEC standalone, 950cc bosch injectors, and more.

I currently am in the process of CNC ing laminova w2a exchangers. There will be two on this setup.
One two core one integrated into a new intake plenum.
one 3 core between the turbo and supercharger.

3 core design
(let me know if this does not show up.


first part of the 3 core exchanger finished on the CNC tonight!
2nd block ready in 51 hours. (it is a simple rapid prototyping CNC, not industrial, so it cannot take out large amounts of material quickly, hence the long cnc time, but hey, its cheap for me!)

 

 

It's beautiful....

 

okay. This is more of a WIP photo from a month or so ago, but here are a few photos from when I started to re-work parts of the engine bay to gain some more usable space.
I have a facelift passenger side motor mount and upper engine mount coming to clear up the pre-facelift damper area so that something can go over there as well. Most likely the flex fuel sensor, a catch can, or the power steering resevoir when it is all said and done.

Look at all of this lovely space!




showing the bottom panel to keep the ABS/DSC module compartmentalized



ECU mount and Gearbox shield
this is 1/4" nylon sheet. and the ecu brackets are 1/8"? maybe 1/4"? I forget, so lets call it 3/16" x 2" 6061 aluminum bar that I bent, drilled, and tapped.

 

Love this thread already and you're just starting. Goodluck with project and keep us posted! Very interesting!

 

well due to a SNAFU made by yours truely, the spindle on the 1/8" bit wrecked into the side (the waste side thankfully!) of the block I was machining and the machine overloaded and error'd out. Thankfully this CNC has an overload protection and we were able to manually wind the spindle up the Z axis and tell the machine to force drop the tool and everything is okay.

This was due to I was trying to make a .95" deep cut and the tool was only sticking out .93".. silly me forgot to re-adjust the tool length as it was fine for the block pictured above as it sat a little higher in the work piece when cutting (.125" higher to be exact).

Luckily we are right across the street from Travers tool (large metalworking supply chain) and I picked up a lovely solid carbide 1/8" x 3" bit and we are back up and running. Put me a little off schedule with the part estimating completion in 14 hours now, but that puts it at 5 a.m. local time, so that is all fine and well by me.



But to hold everyone over, here are some more "prior taken" photos of the injectors I am using!

These are CUSTOM MADE bosch motorsport injectors. They were hand made in bosch motorsport sample shop for the NASCAR transition to EFI. a bunch of them were made, but bosch germany put me in contact with the NY distributor for the race teams and he was kind enough to sell me a set of 4 that were flowmatched for just above what retail ones sell for (and not the $400/injector common with sample shop made units)


These are shorter than the ones in the mini, so I purchased some billet extensions as well. I wanted the shorter ones because when I make my custom IC integrated intake manifold, I will need all of the room I can get.


New vs Stock



Won't find this P/N in any bosch EV14 retail catalog



flow sheet. These are for anywhere from 100% gas to 100% ethanol rated, and are 950cc injectors (~93# for the muscle guys)





And not drivetrain related, but I also just installed a new Orranje GP wing. Had the horizontal section painted white by the people my local mini dealer uses for stripes etc.

 

I can't wait to see results Good luck

 

Wow. Really neat what can be done by one who has skills to fabricate.

Over my head, but love reading about it.

I'll look forward to your updates to this thread, and good luck with your project.

 

Super excited to keep an eye on this thread.

 

I think I am going to need a bigger box as I plan to follow this to then end. Good luck and this is going to be cool.

 

I'm going to watch this one.. nice work!

 

I am so not worthy of even FOLLOWING this thread. Best of luck man and keep us posted

 

badass. real custom fab

 

I've read all of soccer's posts on this so far. What the heck did he say? Really interesting project, but far beyond my knowledge base.

 

crappy cell-phone pic time!

Other piece came off the machine and I decked the back side on the manual mill!

 

Careful about letting out those sample shop part numbers.

Only a Bosch development engineer would know how to look those up.

 

 

You mean like this: http://autopowerparts.en.alibaba.com...M_B289S35.html

Hahaha I'm kidding!!

 

I know, but it used to be my stock and trade... What you found is a GM part number.

Bosch used ten digit numeric part numbers for production in this format: XXXX XXX XXX. IIRC, the first four denote a product division, then a product family, then the individual part. Prototypes use the same format but get a "B" instead of a number in there somewhere. Usually, but not always, the leading digit.

 

This build needs to be done now!

 

I know, I'm just messing with y'all!

 

patience V10climber, There are even more exciting things in due time. Problem is splitting funds between building an appt, putting money away for investments, payments for my DD (2010 GTI autobahn), then this is last...
Still try to work on it some every week though! Just wait until the composite work starts

 

well it's late here and I have to be up early, but here are pictarz! on imgur.. with descriptions on imgur...
http://imgur.com/a/9RXMn


Enjoy!


but as a teaser to force you all to clicky the linky,

p0rn!

 

I love seeing all this custom fab stuff. You using a CAD program for the designs?

 

Using solidworks for the design and a Roland MDX-540 with an ATC and 4th axis for the CNC work.