Hi mate, I have the same caster camber kit as you, it works quite well. I also have the same seats, mine came from an ignis. I found the bases to be too tall so i have just fitted the standard GTI seats back in.

The shell looks really nice, what manifolds do you plan to use.

Cheers
Kev

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my swiftmini @ http://www.16vminiclub.com/forums/viewtopic.php?t=4888

Bit of an update, engine test fit, result - not so good. I've decided to remake the front end of my frame which is half done at the moment, replacing the seperate engine mount housings with a main c section across the front, this will bolt up directly to the body, that way i dont have to worry about spacers. I will keep most of both arms and this front piece will bolt to each arm with 4 bolts each side. I hav folded up a c section and bolted it in, i have made up and pretty well know the position of the back mount, and have a good idea of the front left mount, so i think i'll tack those and test fit, while the engine is in next and roughly in position i'll work out where my last mount will go and mock it up. Here is a pic of roughly where the engine will sit when its done. Thanks to dad for helping to get the engine in.



As for manifolds, intake i'm not sure, depending on what i do for the alternator, i will just use a stock one, otherwise there is a custom made left hand one i can get, which will probably be better for the turbo entry, i was thinking about putting the turbo above the gearbox with the intercooler in the side panel like boostedminis one (except the other side). As for the exhaust, I've got the flange laser cut. I might make up a simple log that runs out to the gearbox, or i might make something with a bit more spaghetti. There is only a short distance to the turbo and then if i can run a short pipe to intercooler and then back to intake, the system whould work pretty well.



Basic Log design, not sure whether to use 1x90 degree and 3xT's or to use 4x90 Degrees cut them and use a bit of pipe. Depending on space, i might have to go 90 Degree down and then a log that is below the panel above the grill (where the bonnet locks on)


Is it worthwhile doing something like this?

Miniboy,
This is what mine looks like:



And let me say it does not detract from the performance. I took my car out for another spin today and when it boosted the torque steer aalmost pulled me into a parked car, so i over corrected and almost took out a wrx coming the other way. Turbo engines and minis are a lethal combo but i am still smiling after todays short spin

Dan

Quick Update:

Engine mounts were a bit in the wrong place and my frame was starting to look abit makeshift. I wanted to put in a brace between the two arms and it was going to look awful. So i decided to start again (kind of). I just cut the front off my subframe. That means both engine mounts and the 2 body mounts are off and I decided to fold up a bit of 3mm steel to a bit of a C section, then mounted it up onto the body to subframe mounts at the front. I have a little lip that comes out under where the mount is (supposed to be spacers) so i couldn't make up one piece and go directly up. So i folded up this C section and made two arms on each end, these will bolt up to the existing arms of the subframe i had made up. Its all looking ok at the moment. I have bought a new engine mount for drivers side front and will test fit the engine and find out where it goes in the next week or so.

Dan: Yeah that is exactly where i was thinking about putting the turbo - did you make up a mount bracket or is it just sitting there on the manifold? Are your runners(4 pipes out of the head?) going directly out or are they 90's that have a bit of a radius and direct the exhaust gases out to the turbo side?

This is my C section - you can see on the left where it will bolt up to the side arms. the piece that is just tacked on will be the gearbox engine mount. I still need to brace the drivers side arm on the front piece, and clean up the arms on the main part of the subframe.


Just a shot of how the drivers side looks. Rear engine mount just the same as original frame.


New frame out of the car, thought i better make sure the engine fits well before i clean it up and finish it off so it looks good.

any updates on this 'un ??

how is your engineer feeling about the folded subframe - I like the rigidity, and the crushability of it. Have you done any FEA on the design?

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did I tell you that I won a trophy?

Coming along ok, i've been on holidays from uni but working flat out to pay off my credit card so the mini took a bit of a back seat.

Engine is in the right spot.
Found a good spot in front of the gearbox for the turbo.
Found a good spot in behind/on top of the gearbox.

So basically the flow will go straight out of the log and one bend into the turbo, out of that and almost directly into the intercooler, i need to get a custom intercooler made or find one that has the intake on the front and one on the side. I am in the process of machining the intake manifold. I have shortened the runners about 20mm and it fits without any trouble. So i'm chuffed about that. I have tacked it up but am having trouble welding up the aluminium with the TIG. So i'll probably take it to someone. I have started machining the end as well so i can reverse the intake. This will mean the intercooler outlet will almost butt against the throttle body. So i'm pretty happy that there isn't much distance between the intercooler and the intake.

On friday i bought some 1 1/2" NB pipe and buttweld fittings so i'm waiting for that to arrive and i can get going on the turbo manifold. I have bought some 2 1/4" exhaust tube along with hi flow cat, some flex and some flanges, I still need to find a muffler. I have already laser cut a main flange from the head but will need to make up a flange for the turbo.

So its all going ok i suppose.

Couple of questions..

1. How much, if any, play should there be in the turbo main shaft. I'd say the bearings would be floating in oil, but is there a way to determine whether there is too much play?

2. Where in Western Suburbs of VIC can you get aluminium welding done? And also custom intercoolers?

Pics of progress coming soon...

Repost...

oi just a quik stupid question (i was thinkin! haha)

wat would be your opinions/ the possibility of makin a custom subframe whilst it in the car??

if you want to ask stuff like this, make a new thread.... instead of cluttering and hijacking miniboys thread

making a custom frame while in the car would be a major pain in the bum because you just can't get access to parts of the subframe you need to weld, and too hard to line up the engine etc.

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did I tell you that I won a trophy?

taking it together in the car would not be so bad. Deans frame was made that way, then fully welded out of the car...

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Starlet Conversion:
http://www.ausmini.com/forums/viewtopic.php?t=15484

Yeah, i'm thinking that its not such a bad way to do it. I designed and built mine outside the car using standard dimensions of a mini but ended up being out of whack due to the shell. When i replaced the front part of the new subframe, i basically sat each piece in the right spot and tacked it up. Then took it all out and welded it up properly.

I was only thinking about this frame the other day. Certainly is an approach I haven't seen prior. Very keen to see how it turns out. I imagine it would be something you could sell some 'plans' for or even manufacture.

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But he's thriving and striving and hugging the turns.

Ok, finally got some pics up of what i'm up to.

Intake Manifold :

Cut Runners to shorten length - machined so flat and level. Shortened to fit inside the firewall.




Machined flange side as well. I decided to butt up parallel but i may need to put a bit of angle in it so i can fit the throttle body.


Just tacked it up - still playing around with the TIG, the tip seems to melt whenever we try so bought a mini roll of MIG wire to try. Good spot though.


Reversing the manifold so the throttle body is on the passenger side - hopefully meaning less piping and more room for everything else.


Turbo Position :

This is what i was thinking for the turbo and the intercooler, the log would come out and do a little bend, then the dump would go back and down under the manifold.


Roughly where the turbo is going to sit. Looks like its going to fit inside the grill and away from the clutch mechanism. Hopefully keeping that semi - stock look.


New hi-flow cat and a bit of flex, also bought 2 1/4" exhaust tube.


Supposed to have got more buttweld fittings during week as well but they haven't arrived yet. So i had to make do trying out with only one. Chucked it in the mill and took out a big chunk of the 90 Degree.


These are the holes i'm grinding out to match the holes from the cut down 90's.


About time i got off my backside and got back into the shed. Hopefully have another update soon.

excellent work there mate!.. looks like a lot of precise work.. not like the good old griding i'm used to! ( I'm sure a few would agree on this!)

Certainly wish I could afford a lathe and mill.. but apart from my conversion stuff,.. I dont think I will be doing anything on them! so a bit of a waste...

The cat converter looks nice.. Where did you get it from if you dont mind me asking? and also $$?? is there a specific brand? how big are the inlet/outlet of your thing?

The exhaust is the next thing on my list so have to get into that.

I read your entire thread and i'm VERY interested in the cad model of the mini you have.. I have some cfd software at home so it should be good to play around with!

please be kind enough to send it to me too [email protected]

Cheers!

Really starting to take shape.

Should be able weld the manifold nicely with a high frequency TIG
You are using Zirconiated Tungsten tips for aluminium?
(not Thoriated like you use for steel)

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Too many cars, and too little time.