2.0 HDI Lexus 6 Speed Conversion

Busta wrote: So how does this work then?
You sit one MDF 'intermediate' mould in the other, fill the void with some kind of wax or melty substance to make a mould then bury that bit in sand and pour in molten aluminium to melt it away?

Bear with me on this

The shiny cavity pattern (core) gets sand rammed into it until it's full to the top....just like making a sand castle.

The other part (plug) gets placed inside an open ended box (flask) and sand is rammed over the top of it until full.

when the sand core is removed and placed on a bed of flat sand and the plug has been removed from the flask full of sand it is then a cavity when placed over the core, through a system of risers and gates molten Aluminium is poured into it and it's kind of like a boolean subtraction.

The lost wax or investment casting is another way of doing it (I'm making an inlet manifold for a buddy using that method)but rather expensive and only for making intricate parts that are too difficult to make with normal green sand casting.

I'll post some pictures of the casting process so you can see it's actually simple....once you get your head around working back to front and inside out

Paul_sterling wrote: great progress Keithy.

it'll be up and running in no time!

Paul.

Cheers Paul

It has to be done before the end of Summer or it'll be next year

Any particular reason for using the hdi 90 over the hdi 110?

OllieNZ wrote: Any particular reason for using the hdi 90 over the hdi 110?

more readily available, smaller turbo, but more so because the aim is torque rather than outright HP in Keithy's case I believe.

cheers,
Paul.

Paul_sterling wrote:

OllieNZ wrote: Any particular reason for using the hdi 90 over the hdi 110?

more readily available, smaller turbo, but more so because the aim is torque rather than outright HP in Keithy's case I believe.

cheers,
Paul.

Bang on!

If I was after power I'd have a turbo on the M13 or M16......I use this car everyday so it has to be long term reliable.

And I got a complete car cheap

Keithy wrote:

Paul_sterling wrote:

OllieNZ wrote: Any particular reason for using the hdi 90 over the hdi 110?

more readily available, smaller turbo, but more so because the aim is torque rather than outright HP in Keithy's case I believe.

cheers,
Paul.

Bang on!

If I was after power I'd have a turbo on the M13 or M16......I use this car everyday so it has to be long term reliable.

And I got a complete car cheap

It was not so much of a question of power more of the fact that the 2.0 110 hdi is more economical and more tunable, afaik the core engine is the same it's just the bolt on gubbins like the turbo etc that are different.
Using it because you've got one is fair enough, do you know if it has a bosch or seimens ecu?

OllieNZ wrote:

Keithy wrote: It was not so much of a question of power more of the fact that the 2.0 110 hdi is more economical and more tunable, afaik the core engine is the same it's just the bolt on gubbins like the turbo etc that are different.
Using it because you've got one is fair enough, do you know if it has a bosch or seimens ecu?

It's a Bosch unit 15C2 single plug.....I think

Originally it had a 3 plug ECU on it but getting a wiring diagram turned out to be tricky......I found one in French but it had too many references to "masse" on it so moved to the 307 unit which has a better wiring diagram ie I may dare to plug it in!

Keithy wrote:

OllieNZ wrote:

Keithy wrote: It was not so much of a question of power more of the fact that the 2.0 110 hdi is more economical and more tunable, afaik the core engine is the same it's just the bolt on gubbins like the turbo etc that are different.
Using it because you've got one is fair enough, do you know if it has a bosch or seimens ecu?

It's a Bosch unit 15C2 single plug.....I think

Originally it had a 3 plug ECU on it but getting a wiring diagram turned out to be tricky......I found one in French but it had too many references to "masse" on it so moved to the 307 unit which has a better wiring diagram ie I may dare to plug it in!

I'm not 100 percent up on the exact ins and outs of the individual ecus I'd pop over to the 406oc forum (if you haven't already) some of the guys on there should be able to help out with wiring diagrams etc. I also have pp2k if that's any help (and if you're anywhere near me)

OllieNZ wrote:

Keithy wrote:

OllieNZ wrote:

Keithy wrote: It was not so much of a question of power more of the fact that the 2.0 110 hdi is more economical and more tunable, afaik the core engine is the same it's just the bolt on gubbins like the turbo etc that are different.
Using it because you've got one is fair enough, do you know if it has a bosch or seimens ecu?

It's a Bosch unit 15C2 single plug.....I think

Originally it had a 3 plug ECU on it but getting a wiring diagram turned out to be tricky......I found one in French but it had too many references to "masse" on it so moved to the 307 unit which has a better wiring diagram ie I may dare to plug it in!

I'm not 100 percent up on the exact ins and outs of the individual ecus I'd pop over to the 406oc forum (if you haven't already) some of the guys on there should be able to help out with wiring diagrams etc. I also have pp2k if that's any help (and if you're anywhere near me)

I'm in Leeds, I'll be taking a deeper look at the ECU side once I have the engine and gearbox together....with attendant clutch

Mostly with the ECU it's going to be removing the EGR, Immobiliser,AC..door detection....way too much when all I need is for it to run!

I'm in Oxfordshire so a bit far away. Good luck with it. I'd like to see one for the 1.6 110 HDI engine, they cop alot of flack but 90% of their issues are due to their emissions control systems.

OllieNZ wrote: I'm in Oxfordshire so a bit far away. Good luck with it. I'd like to see one for the 1.6 110 HDI engine, they cop alot of flack but 90% of their issues are due to their emissions control systems.

My C2 is powered by the DV6 (1.6 Hdi) 110bhp engine. had it 7 years, 80,000 miles since new (I bought it new) and it is brilliant.

Paul.

A 1.6 16V? would have been fine....same bellhousing bolt pattern?

I should be outside making moulding boxes (flasks) Naughty aren't I