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?