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BennyBoo

BennyBoo's Noggy

Reet, Here goes, My first Topic about my car..

So far, with 2 years of ownership, I love my Noggy to bits. Totally what I want out of a car, fast fast fast with no specific mean to telling how fast it is haha and it looks like a boring 4 door german saloon (beat a Ferrari 458 Almost, kept with him until about 60...)

Anyway, I'm bored of the fastness.. I need more speed!

So far I have bought...

A pair of Volvo KKK K24-7400. A 300hp standard (With 5cylinders) turbo on it's own. I have got 2 hotsides, 2 coldsides, the turbo's are complete, but one has a bent shaft and the other has damage to the compressor wheels.. I'm thinking of just buying new CHRA's and building them standard.. OR Trying to find some smaller hotsides (K16's from a porsche maybe..) Got them for £60 posted..
I'm hoping to get at least 500 from these, then use them at full potential when I'm three litre.

RS4 injectors. Which i'll probably need to sell on when I want more than 500hp.. Got these for £70

RS4 Rods. Will my standard S4 pistons be ok? (I've heard they are Forged Mahle..?) I want to go 3l eventually, so hopefully I can get away with these until I buy new ones for then.. Got the Rods for £107 posted, but won't tell you where

That's it.. I'll be getting all new bolts, seals, gaskets and whatever else on the next month or so as well as getting the biggest front mount intercooler I can get in there and doing some custom pipe work as I WANT to keep the fogs. I'm also on the hunt for some 2.4 heads (BUT CHEAP probs find a whole engine on eBay and get lucky with the heads lol) to help with spool..

What do you guys and girls think..? Bearing in mind what has been said already, I know the turbo's are going to be laggy, I should really just stick with boring old K04's, blah blah, But I wanted something different/hard/impossible (delete as necessary)

What have I forgotten, what should I include? (I know about Brakes, Clutch and flywheel, but I have a few ideas..)

Thanks!

P.S. I'm trying to think of a name for my build.. Something along the lines of Cheap Scruff4, what do you guys think?
CraigG

Re your turbo choice, i think laggy is not going to be the word for it.

they are designed to push 300bhp connected to a 2.5L engine.
your attaching it to a 1.35L engine

imo you should most definetly go for K16 hotsides
frazz82

You seem to be very jammy with getting things for a bargin price..........good effort  

Be intresting to see the results, when are you thinking of starting your build
BennyBoo

Should start early summer hopefully..

Or whenever the parts arrive haha.. The turbo's might be dirt cheap for a reason.. The guy may well be haveing a massive beer sesh with my money right now lol

Rods should be here Friday though
nogaro s4

pics or none of its true    
BennyBoo

Haha, Pics as soon as everything arrives

also, put an offer in for two k16's today
will1981

Who is doing the engine work Benny?
will1981

Who is doing the engine work Benny?
Geeman

Hmm... would go even faster if you got some paint sorted out. At least another 25bhp. lol

I'll be interested to see the bits n bobs get built up.
BennyBoo

will1981 wrote:
Who is doing the engine work Benny?


Me, then my mechanic mate when I c##k up

Geeman wrote:
Hmm... would go even faster if you got some paint sorted out. At least another 25bhp. lol

I'll be interested to see the bits n bobs get built up.


Yee, will do the paint Gee
nogaro s4

BennyBoo wrote:
Haha, Pics as soon as everything arrives

also, put an offer in for two k16's today


i meant pics of your car matey members car thread with no car pics boooooooooo      
BennyBoo

Love it when the wife texts me to say 'weird things keep coming through the post'

No turbo's yet..



(They're not Pauter Rods )
Geeman

You know she's going to know about EVERYTHING that you buy for it now... as you can't get parts sneakily delivered to work now!

If you need to get things delivered, you can always use my address bud.
BennyBoo

Nah, don't worry Gee, I can still get stuff sent to the Town Hall now
BennyBoo

Offer for K16's denied..

There's 2 on ebay atm from the same seller, £150 each..
BennyBoo

One CHRA turned up today.. With a bent shaft..

It's huge! (that's what she said) I'll use it to build the turbo's together again and see on fitting..

where should I get CHRA's from??

Or should I pay someone to go hybrid now?
BennyBoo

Still no K24's...

Should be here this week though (He's promised...)

We'll see!
BennyBoo

AND still no K24's..

Hmm, this build has died a death so far..

I'll have to take a pic of te things i've bought and list everything I still need..

You guys can tell me where I can go better (except Turbos ) and where to try something new
BennyBoo

Well I had lost all hope with the K24's being delivered..
Guy's turned his phone off and not visited the Volvo forum i've been fequenting for some time..

Got the mods involed and got his address, with advice to go to small claims court..

but this weekend..
All sorted

All I can say is that the Volvo crew don't F**k about!

I was at a show over the weekend (Elsecar, Barnsley) and this guy I found lives in Rotherham, be rude not to pop in for a 'discussion'..
Although, he wasn't in Posted on the Volvo forum i've been dealing with what i'd done and a Mod, from Castlford, got wound up and travelled to, and I quote, "the little tw*t's house" and got my bits for me. Very happy.

They'll be with me on the weekend as the Mod is hand delivering them.

I'll post pics of said K24's when they arrive  
guymcc

Sweet! Good result
Hoyle

Volvo owners - can't beat 'em!

Looking forward to seeing some progress now.

Are you just going to stick with RS injectors and then upgrade to 630's at a later date? Which fuel pump are you using?

Hoyle
BennyBoo

Thanks Hoyle, i'm wanting to find my RS injectors..! Had them for sale a month ago as I knew i'd need to go bigger, cleared the garage out and now I can't find them.. But i'll probably try and find a good price on some 630/660's.. Fuel pump wise I don't know yet, how much is the RS rated to? Or should I try the 044..? Or something different...
MathiasS

BennyBoo wrote:
Thanks Hoyle, i'm wanting to find my RS injectors..! Had them for sale a month ago as I knew i'd need to go bigger, cleared the garage out and now I can't find them.. But i'll probably try and find a good price on some 630/660's.. Fuel pump wise I don't know yet, how much is the RS rated to? Or should I try the 044..? Or something different...


Get the Loba in tank Bosch kit for 240£  
Hoyle

I was going to suggest the 044 or perhaps a Walbro.

If you're chasing big numbers, then the RS4 pump will be a bottle neck.
BennyBoo

Right..

I need to source some Compression dropping headgaskets, Clutch/flywheel combo and injectors/pump at the mo..

Another complete K24 found and 2.4 heads to be paid for at the end of the month.. So other stuff has to wait till next month.. But give's me time to search for different hotsides..

I'll have to start taking some pictures!
BennyBoo

Postman loves me

30Kg box of heads and another huge turbo..


Geeman

What's the latest bud?
BennyBoo

Nothing yet ..

Need to buy Injectors, Pump and Clutch.. (and Cambelt Kit)

Works getting in the way of actually starting it.. But i'm starting it after AITP
BennyBoo

Work has started!

Up on axel stands without springs/shocks..

Stuff is selling quite nicely, enough to buy another K24 anyway, so that's 3+1/2 i have

I now have 2 refurbished ones, and one spare, with another hotside and another coldside and one almost complete (without backing plate CHRA) 'just incase'

Think i'll start another thread on the build once I start with the engine out stuff


Liking all the support I'm getting, thanks guys, you know who you are


Edit: Also found out the other day that the KKK K24-7400 is the biggest K24 Borg Warner make
frazz82

Looking forward to seeing this mate.

Don't forget the pics.

Whats going to be for sale ?
BennyBoo

frazz82 wrote:
Looking forward to seeing this mate.

Don't forget the pics.

Whats going to be for sale ?


Cheers dude

http://audisrs.com/about38012.html
BennyBoo

And another refurbed K24 has turned up. That's turbo's and heads to be working on soon. Need to get the car turned round, into the garage and get the front off / engine out.

All i need now is a clutch kit (which I'm about to start a thread on) injectors, fuel pump and cambelt kit / gaskets...

So much to be getting on with too!
LeeT

Nice one ben, look forward yo the progress. I think i might rip my engine out next weekend too. Mot is out now so why not?
BennyBoo

Little update..

It's back on the ground and in the garage..


It had to go this low as I 'had' to cut the springs as I was in a rush to get it in the garage.. It won't stay like this.

Exhaust is here, just need a bender



Neighbour Pleasing

When putting the rear springs on I checked the dreaded back plate.. And was treat with this..

Not too shabby for 12 years old and going by recent people's rears..


Time to get the bumper off and get that little lump out..
HEKTOR

Loving how low the front sits.
ruxy

Are you making it in to a limo with all that extra exhaust?  
BennyBoo

To be fair I didn't know how much I needed but at £75 for a 6m length I couldn't go wrong..

Lets me have the option of missing out the xs-power link pipes straight into this I guess..



Front is lowwwww
monkey76

Bet you guys save lots of monies doing your own stuff, unlike I bit of a thicko when it comes to mechanical stuff.
ruxy

Is it 2.5" or 3"pipe? Are you having a crack at bending/fabing it yourself?
BennyBoo

2.5", I thought may as well go for that than 3" as the downpipes go from 3" to 2.5" anyway..

Yee i'll bend it myself, only a couple of bends to do..

Just need to fit the downpipes first to make sure they are in the right place to start with...
BennyBoo

Smaller update..

Tidied my garage up.. Now I have room to work around the car..

I'll be raising it on stands again and dismantling the front anyday now



Lag Beast is almost go!
BennyBoo

Finally!

Started, raised on stands so I can get underneath and the bonnet is off to allow light into the engine bay at night..

Who knows, I might get the front off next year!
audimad100

Jesus Ben, those are the biggest Hot sides ive seen being thrown on an S4. think you will struggle with the quarter mile but it will be all shits and giggles after that when they spool up      
LeeT

audimad100 wrote:
Jesus Ben, those are the biggest Hot sides ive seen being thrown on an S4. think you will struggle with the quarter mile but it will be all shits and giggles after that when they spool up      


Its tight enough squeezing ko4's in there, let alone these monsters  
Good Luck!
BennyBoo

audimad100 wrote:
Jesus Ben, those are the biggest Hot sides ive seen being thrown on an S4. think you will struggle with the quarter mile but it will be all shits and giggles after that when they spool up      


Haha, they are a little big.. Im kind of hoping they give me a bit of lag then a kick in the kidneys, abit like the S/RS2 power delivery and really hope its not gonna be like driving a derv.. (spool spool spool,  bit of boost!.. Change gear..)

LeeT wrote:
Its tight enough squeezing ko4's in there, let alone these monsters  
Good Luck!


Ill hammer the crap out of the gearbox housing..

But yes, i think this was the main concern.. I need space for the external wastegates too!
BennyBoo

My God, I've had another hour on her..

Removed most of the top of the engine, airbox and MAF..



Found out a previous owner had done this


For Sale - http://audisrs.com/sutra497976.php

Can anyone identify this fiilter..? Stock?




Work stopped as I lost my bit when removing the last bolt off the inlet manifold.. D'oh!

Who knows, at this rate it may get finished!
audimad100

could be a K&N filter, i have the pipercross one which looks very similar but has 4 different layers of foam
PaulyRS4

It is a pipercross filter.
audimad100

the underside of my Pipercross is totally different to that one, but yes it could be
monkeyrs6

Agree pipercross same as mine but does your airbox have a rodant infeatation.  
S4BiT

Looks like a Pipercross, K&N is pretty much different.
BennyBoo

Front bumper and front panel off, almost had the front panel off,  got in abit of a faff when i accidently started undoing the aircon connectors at the radiator..! Oops..

Anyway, front completly off, so have access to the front of the engine now

Am i right in thinking i can just lower the engine a little from this point to then get access to the turbos..? If not,  i guess its just as easy to pull it forward and out instead..?
LeeT

You need to pull it out to work on the turbos.
BennyBoo

LeeT wrote:
You need to pull it out to work on the turbos.


Cheers

I'll have to wheel it out and in everytime then
BennyBoo

Another quick sesh this morning saw the front panel completley off now..



Then the intercoolers..



Passenger side intercooler was full of .............................. Water!?

So was the inlet manifold..

And this is what greeted me underneath that..

Noggymike

Bet that made your day
ruxy

I'd change that secondary water pump while your in there
Admire your bravery here, looks like your having fun though and keep us updated
jimbo

youll soon regret all that lag.    
S4BiT

This afterrun pump is known thing to oxidize/corrode and leaking because of that. But how this water got into intercooler?
ddidds

Ben this is MASSIVE !

can't wait for the end results !
BennyBoo

jimbo wrote:
youll soon regret all that lag.    


im hoping for boost by 4.5k... Im still on the lookout for cheap K16's

Im hoping for                    

Cheers for the support guys
jimbo

what, starting to boost or full boost?
BennyBoo

At least starting..!

Maybe full by 5/5.5?
jimbo

lol. youll hate it      
BennyBoo

Fingers crossed for k16's then

What you running now..? Which K24 setup did you end up with in the end..?
BennyBoo

One for the mods..

Can this be separated and popped into the "Projects" section..?
BennyBoo

Small update, been busy at work so not much done..

Wiring loom seperated, exhaust unbolted after cats, engine/gearbox mounts undone, rear prop almost undone..

Ready for the first lift! Just need to seperate drivshafts and be careful of whats still connected behind the engine i guess..?

frazz82

Coming along nicely ben.

BennyBoo

Engine out Tuesday
BennyBoo

AAAAAANNNNNDDDDDD it's out..

What a fooking ballache it was too!

All them guides on removing the block, ignnore them

Well, my DAY started at 0900, arriving to pick a father inlaws people carrier, to find it's one big block of ice, 1000 arrive at Stoneacre's to use their engine crane at home, arrive home at 1130.

Let's crack on

One last thing to do (as i was borrowing a mates 6mm allen bit) was remove the prop.

5 bolts came out fine, but the last one was the one i couldn't reach, moving the back wheel round didn't help as the handbrake was stuck on! Hmm, last option (i tried reaching it from the top..) was an angle grinder. So that's off, Jimbo, bolt please

Crank the engine up, careful Ben, you might have forgotten something plugged in.. Nothing, everything is removed Crank a little more, crane stops..

Crane turns out is low on fluid.. ok, lower the car, crank up with more room Crane starts to lean..!

turns out the crane is a shit heap, no wonder they let me borrow it. Fix the crane before I use it.

1600

start lifting the engine again, it comes up well and I can see that it's going to miss the subframe, start to pull, nothing, pull pull! nothing.. Lower it, lift a little, pull, something!

Goes on like this for a while, started to lift the gearbox and all's going quite well.. If not far longer than it should!

turns out it's not coming anymore as the driveshafts are getting in the way.. pop the engine almost all the way back in to get them out of the way..

pushing and pulling for what seems like forever, everything is out of the way, nothing is connected anymore but it just won't budge..

Everytime I move it, it falls back in. mix of crap crane and downpipes getting stuck and me getting knackard.

End of the day 1930, and it's out. only to realise It wont go on the crane as i've removed engine and gearbox, and they only gave me a stand to attach to the bellhousing..

so another 45 mins of me trying to get this shite crane moving to get the engine next to the car..

I'm knackard, pissed off and emotional

here's how it sits, and it will for a week or so. I'll strip it here and hopefully get it on the stand for rebuilding!



Thing is, i'm not a big guy, 10.5 stone but i'm no wimp and I know i had limited space.. I just can't believe it took me this long to get the block out..

Thought of the day, It's going to take you longer than you told your wife it will..
Geeman

BTW... I have an engine stand. Might not fit, but you're welcome to try!

P.S. I've never seen an engine stand that will take engine AND gearbox.  

P.P.S. Well done son!  

P.P.P.S. It ALWAYS takes longer than you told your wife it would. Fact.
frazz82

Good effort ben  
Noggymike

If at first you don't suceed.......

Great effort
BennyBoo

A couple of K24-7400's vs K03's..







Moggy Approved

BennyBoo

Specs on said K24..

The turbo 5324 970 7400 (K24-7400 abbreviated) has the following spec:
K24.2-2474DXBAA6.81GAAXM
C.W.:
O.D. – 62mm / inducer – 45.8mm / ETT (Extended Tip Technology)
T.W.:
O.D. – 59mm / exducer – 50mm / tip – 9mm / 5.4mm stub shaft dia.
TH:
6²cm area / set pressure – 7 bar @ 7mm lift

Anyone have any similar for the K03..?
nogaro s4

nice work matey

what volvo is that turbo off? a T-5?
BennyBoo

Yaaaaa, the Volvo T5 V70/S60 AWD 300hp models
Or (slightly modified) the Ford Mk2 RS

CORRECTION! The Focus has a K16... as found in the T5 C30..
nogaro s4

BennyBoo wrote:
Yaaaaa, the Volvo T5 V70/S60 AWD 300hp models
Or (slightly modified) the Ford Mk2 RS


you nutter    

lag.com

i miss my old 850R saloon manual  quick but what a laggy so and so
BennyBoo

Bagged myself some K24-7000 exhaust and turbine houses..

Use the same length CHRA as the 7400, slightly smaller wheels, but exhaust housing shouldn't need machining, just the Turbine will need machining and the 7400 backing plate will need turning down to the 7000 size.. Also are already External Wastegate, so no more modding needed

This will help spool out an awful lot! But will limit my power to only 320whp... Per Turbo..

I can live with that..
BennyBoo

I've asked a mate, who makes stuff out of metal to make me a few things..

Solid Engine/Gearbox mounts, adapter plates for my turbos/exhausts, rear diff mount.. He knows a guy who can do manifolds, but i'm not holding my breath with them being cheap..

Shall I get some solid mounts made..?

This car is becoming more and more raw..

I was thinking of going for smaller 17" wheels for cheaper track tyres.. But would that limit my choice of brakes too much..?
BennyBoo

Well, some more Turbo's turned up..

I'll be using the 7400's chra's in the 7000 housings..

Spot the models















Things are being sold off too, quicker than I hoped, so all goes back to the modding fund

Still no move into the P+B section mods..?
BennyBoo

Update time!  Ive been working pretty much everyday these past few months, nit alot has happened..

Had a few lines of enquiry and im now set on relocating the turbos to the sides of the heads..

Turbos are half built, just need the coldsides machining bigger..

Ive made a list of the final parts in want/need to buy, im actually in profit from selling things off the car i dont need and with all the things ive bought.. Which is a plus, not like ive been selling things for mega bucks!

Still got more to sell too, so im doing well in the wifes eyes

Having a full day Sunday on the engine, so hopfully heads, gearbox and sump will be off and mounted on the stand.. Heads for sale after inspection

Back to the front page for the lag monster
BennyBoo

Well only had a couple of hours on it today

How the feck does the Viscous fan/mount come off!?

Getting smaller..


These look alot cleaner than I thought..








Needs a quick tidy

BennyBoo

Well, Heads and Gearbox off, Getting dark so I couldn't get the block on the stand..


Heavy bit of kit that!

When I took my inlet manifold and intercoolers off, the Passenger side cooler was full of water, as was the inlet mani..

This is how I found my block and heads..

Driver's Side




Passenger Side




This ok? Been stood for about 9-10 months..
audimad100

head gasket could have caused that. need to pull the pistons and get the block honed out to make sure there is no pitting that could make the rings pick up
calibra_se8

Some good progress

The viscous fan is ona  reverse thread so clockwise to loosen. It's difficult to counterhold the pulley while loosening.
BennyBoo

audimad100 wrote:
head gasket could have caused that. need to pull the pistons and get the block honed out to make sure there is no pitting that could make the rings pick up


That's what I thought.. Will have been honed and checked prior to rods being put in Taaaa

calibra_se8 wrote:
Some good progress

The viscous fan is ona  reverse thread so clockwise to loosen. It's difficult to counterhold the pulley while loosening.


Cheers man

Yep, already on the Viscous case, it's a toughie! Not got a spanner that big...
BennyBoo

Updates..

Nothing much  has happened recently due to work and homelife.. Just had the garden landscaped..

Complete 2.8 heads bought
Some 10mm laser cut flanges for my manifold build
Turbo houses ported to fit the wheels
Started stripping the 2.4 heads

Almost bought an all road .56 6th but heard you need 2 cogs..?


Few things sold, few things researched..
BennyBoo

Started planning on relocating the ABS module..

Before I go full hog, it's fine to just remove and rebleed when all fitted right? I'm sure it is, but you never know..

Aircon pump's a bitch to get off..!?
BennyBoo

2.8's have arrived, not even unpacked them i'm that busy..

Get on them this week

Almost on the verge of finding some conrod shells for my rods.. I might be saying bye bye to RS4 tax

Does anyone see the light at the end of my tunnel..?
ruxy

Keep plugging away mate
BennyBoo

Slow and steady..

Two sets of cylinder heads stripped, 1 set of 2.4s rebuilt.

They'll stay built hand tight like this, as I don't know how long it would've been apart!

So, one set of bare, clean 2.8s for sale..

Ive used the standard 2.4 heads, complete, but using the 2.8s cams.
BennyBoo

God its slow going.. Only get an hour here and there

2.4 Heads fully built with 2.8 camshafts. Well almost, until the last bolt for a cam cap snapped on me! Grr!

Clutch and flywheel removed..

Doesn't look too bad having been 4.5k launched for about 5k miles..!  







Aircon removed..




This week i'll be mostly cleaning out the garage and back of the car, get on with removing and advertising saloon rear stuff.. Hopefully get more room in the garage by removing a bed in there.. Might even build myself some shelving
BNBboyo

[quote="BennyBoo:497734"]
audimad100 wrote:

I need space for the external wastegates too!


Nout beat's twin screamers ....ftw!  
BennyBoo

[quote="BNBboyo:556354"]
BennyBoo wrote:
audimad100 wrote:

I need space for the external wastegates too!


Nout beat's twin screamers ....ftw!  


Yeeeeeee im toying with the idea to have a quick release section on my downpipes (half of them will be in the bay as im having top mount manis) to then route a section of large pipe out the bonnet/wing for dyno and drag days..
BennyBoo

Wow, i've been so busy lately..

There will be an update next thursday night, after I get to have 2 whole afternoons in the garage!

Sorry to all those following
BennyBoo

Whhhaaaayyyy



Finally, after a year, it's on a stand. Now the block can be stripped and cleaned down, then off for honing..

Everything else can be cleaned/resealed and put into storage lol
Noggymike

Good work

Hats off        
BennyBoo

Cheers Mike,

bit of a struggle juggling work and family life at the mo, the S is missing out!
HEKTOR

Good to see you are progressing. Im really looking forward to seeing how your project finishes... Should be cool
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