Volvo Daf 66 Gordini Turbo

[SwissDave]

those CVT units use vacuum to change their ratios up (as well as centrafugal weights).....very large diaprams ....you dont want the turbo pressure in there!!

You're right, that's why I'm using a stand alone vacuum system with a 12v vacuum pump from an electric car braking system. I have also added extra switches inside the car to manipulate the vacuum supply to the variomatic so that I can hold higher revs when I want to.

 

[SwissDave]

The oil return from the turbo to the sump is now done, it slopes downwards all the way but I have had to clock the turbo centre a few degrees so that the oil return fitting on the bottom of the turbo could clear the manifold pipes.
The inlet pipe to connect the turbo outlet to the inlet manifold is done too, I have had to order some special fuel proof silicone hose for the connecting bend and to join the carb plenum to the turbo inlet as the fuel rich mixture world eat through standard Samco hose eventually. As this was a special order in 60mm ID I have gone for the classic matte black colour. A sign I'm getting older I guess, it would have been blue or maybe orange hose I'd have wanted 10 years ago..

 

[SwissDave]

Another month gone and although there has been a lot of progress with little fiddly jobs the engine bay looks pretty much the same.
I made a support for the turbo as it's quite heavy and the fancy new manifold wouldn't last long with it bouncing up and down,
As these type of manifolds are prone to expanding and moving as they heat up I have used two cheap rod end bearings on an 8mm stainless rod so that the turbo can move away from the engine if necessary but is protected from up and down movements.
The expensive fuel proof Samco hose has arrived and looks lovely and I have sorted the coolant feed and return for the carb plenum, a t-piece from the heater supply feeds the back of the plenum and the return from the carb base is teed into the thermostat bypass hose. It's getting close to first start up now, hopefully by the end of this month.
Some pics of the turbo support;

 

[Adey]

fabulous work. I love reading up on all these quirky different builds. Keep it up

 

[DaveL485]

Did you make that threaded rod yourself?

 

[SwissDave]

No, these guys do lots of little bits like that for me lynnmore engineering - Google Search
They are a stones throw from work and very reasonable. They made this stainless t-piece for the heater hose to carb plenum plumbing last week.

 

[SwissDave]

The cooling system is finished st last, I had overheating issues on hot summer days with a recored Daf 66 radiator after I fitted the Gordini engine and the new engine spec I'm working on will make a lot more heat so I needed something better.
I have used an alloy rad commonly fitted to kit cars which is based on an early VW Polo type. These came to be popular as their small size fits into the nose cone of a Lotus 7 type kit. They are readily available and a lot cheaper than a bespoke exact replica. I needed to make some mounting brackets and change the bottom hose position but it was all straightforward if time consuming.
I've also fitted an oil cooler, this was a cheap eBay 5 GT Turbo kit with a thermostat in the sandwich plate. I have mounted the cooler in the front bumper.

 

[SwissDave]

I have managed to source a new genuine Gordini Turbo spec carb from Italy, the one that came mounted on the inlet plenum I had bought wasn't an original 32 DIR but some strange one from another Renault. I tried initially to get a good used one but as I'm mounting the carb above the exhaust manifold I thought it safer to try to fit new. I'm also using a Malpassi filter king pressure regulator inline from an electric fuel pump, the pump is only a low pressure one to suit a carb but better safe than sorry. The fuel pump also has an inertia switch fitted to the power supply in case of a crash.
I need to get the engine running over the next couple of weeks, the exhaust guy I use has it booked in to have the turbo dump pipe to exhaust piece made at the end of January and that should be everything done.

 

[Adey]

good work on finding the carb. nowt like a deadline to get things finished. Are you planning to get it all setup afterwards too?

 

[SwissDave]

Yes there is a local guy where I had the Gordini spec done a coupe of years ago, once running a standard Weber and also on twin 40s. He is great on carbs and got it running really well. This is the rolling road video with the 40s;

 

[SwissDave]

It’s alive! It fired straight up and ran for a few minutes for the first time today. All good, it’s a bit fluffy but it was smooth once running and though I hardly dare say it for fear of cursing myself but there are no fluid leaks so far.
The one problem I do have is that it squashes the silicone hose from the turbo outlet to the cross over pipe under vacuum when the throttle is closed.
I now understand why the standard Renault 5 plumbing is a solid alloy pipe. I think I need a hose reinforcement spring in there.

 

[Adey]

good work, vids are needed

 

[SwissDave]

A spiral made from 2mm stainless rod fixed my hose problem, it’s enough to stop the silicone hose being crushed by the vacuum.
The fancy looking oil return fitting turned out to be crap and leaked do I have replaced it with a simpler barbed oil outlet fitting on the turbo and rubber hose covered in a heat shield.
I found a carb top filter adaptor from a NA Gordini engine the other day that I had forgotten I had and will be using this as it’s nice and shallow to connect to an air filter somewhere on the cold side of the engine.
The car left on a trailer today to get the turbo to exhaust link pipe made, it should be back in a couple of weeks for the final bits and pieces.

 

[Adey]

tidy work, i use the same heat sheathing on some of my lines that are close to the manifold, had no issues yet

 

[SwissDave]

I will be collecting the car on Wednesday but I went to have a look this morning. The turbo to exhaust link pipe looks great with a boss for the lambda sensor and a nice flexy piece before it joins the exhaust. The Classic Swede made system I already had fitted is 2” stainless with 2 straight through silencers, it was always a little on the loud side with the atmo engine, particularly cruising at 4K revs plus on the motorway so I’m hoping the turbo will quieten it down a bit.

 

[Adey]

tidy work, ive ran 2 inch straight through exhausts on my gordini turbo and le car 2 turbo. They were, for me, perfectly acceptable to drive around with and cruise with. The turbo kept the noise down, well until on full chat :ag:

 

[SwissDave]

I’ve been driving the little car for a few weeks now trying different jets in the carb and fixing problems as they’ve (frequently) occurred. And the conclusion is (Tony Smith I did try and quote you but I’m hopeless at this sort of thing) that the compression ratio won’t stand any worthwhile boost without pinking. The throttle response is lousy and I plain don’t like it. To cap it all the turbo blew it’s oil seals today and the intake is swimming in oil.
So I’m going back to twin 40 Webers for the time being and will come back to the turbo idea with a more cohesive plan in the future, lower compression, injection and management maybe. The only expensive bit was the manifold and that can be reused with any T3 flange turbo. As the great Arnie once said “I’ll be back!”
Thanks for all the interest.

 

[Adey]

ive liked the post but i think that deserves a dislike button! how pants, to be fair even in stock form the 5gd turbo suffered from pinking, especially when warm or on long pulls. The comp ratio shouldn't really be an issue if you went full efi with it. Shame its not come together. Have you thought of going blow through using a 32dis? they are a little laggy with the bigger blower but i wouldn't ever say unresponsive. Mind if you have been used to 40s it would be a completely different delivery of power.

 

[Brigsy]

What ign setup is it on ? The stock suck through gordini setup is pretty pants even on the low comp lump - 10.5:1 is asking for loads of knock.

Efi and a charge cooler or intercooler setup, drop the compression a bit and add a modern turbo - will be great

 

[DrKd]

Looking good on your progress. Take the pistons out and machine the dome i.e. flat top the pistons. Mine are still in the box ready to do lol