1994 Rover 820

and final unfinished task update is engine mounts and stabiliser, cut and pushed out the soft rubber original bushes now to find suitable solid replacements, off course there is nothing the exact size available so need to make up sleeves of some sort.

Engine mount





Stabiliser, this I might just replace with rose joints



That is where it is at the moment Jim, very slow progress, but hope this will give me the kick I need to get back on it, thanks.

Thanks Kelvinator, they are still cheap over here but low mileage rust free examples are difficult to find, I was going to say still plenty about but just searched ebay and only 1 listing!

Spent half the day in a very very hot garage yesterday trying to make progress on the exhaust manifold, losing patience with it trying to line it all up so everything is in the best position. Getting close to cutting my losses and shipping it off for a custom manifold.

Managed to get a few days in the garage trying to get the turbo and downpipe in position. No matter how the turbo was positioned with the downpipe fitted there was something not right, to far forward, to close to water pump, downpipe to close to sump, angle from the manifold to turbo to sharp.
In the end this was the best position for the turbo with all the compromises so the downpipe was routed with enough clearance. It meant a really sharp angle but maybe I could just about get away with it.
With bits of wood taped all round the sump, engine mount water pump etc more wood propping up the turbo this was where it ended up



Next was cut the sections to join the manifold to turbo



Day 2. It was no good could not convince myself this was right, besides the flange was a curse word fit at the turbo. Wasted many hours but was never going to be happy with it like that.



Only way is to start again. Get the turbo in the best position then work back, means chopping up the new downpipe which I wanted to avoid but got no choice the shape is to far off.

So to start again, had a new 12mm stainless turbo flange made to match the turbo intake, near perfect match and with threaded bolt holes and a tab so I can add a support bracket.



Turbo in optimum position, new sections were made to join the manifold to flange for best gas flow and clearance. I was on a roll at this point and forgot to get pictures so it jumps to tacked into position and partially welded



It will need some tidying up inside to blend the downpipe tubing into the smaller rectangular turbo intake but should get away with it





Front section fitted. Not the best welding but I might attempt to flatten it all afterwards if it stands out to much, great thing about stainless steel it polishes up like chrome quite easily.





Lastly for now made a start at grinding the sharp edges inside and blending the tubing to the flange



More progress soon hopefully

Thanks, plan in my head is to build a little frame or a plate fixed to the block to attach it to.
Just ordered a long burr for the die grinder to blend inside where the pipes enter the collector.

nice! did you get away without much warpage on the flange (i read this is why OEM's were welded on the inside of the tube, despite the bead hindering flow)

i remember seeing an exhaust turbine get white hot (in a rolling road) and you could see the shadow of the impeller through the cast

Thanks Jim, the welding is terrible so expecting a bit of repair work after it has been used.

I had to cut and bend the downpipe to clear the sump, it still passes a little close to the sump but should be ok. After patching up the hole I came to two conclusions, I really need to improve my welding skills and this downpipe will probably be cut and joined again in the future.
When it comes to building the system I plan to set up a temporary welding station with a bench I can sit at with the pipework properly supported at the right height and practice first.



anyway it fits so I can get on with the system now.



I went a simpler route with the top hose, the first attempt was to many parts to long and looked wrong, this still has some flex so engine movement does not pull on the radiator and is much neater.



It still passes close to the exhaust manifold.



So made a little aluminium heat shield to sit between the hose and manifold, it needs finishing but should do the job.



Because the turbo is now in a different position the intake hose, oil feed pipe and coolant pipes need extending or adjusting one way or another I have some new parts coming this week to sort those out.
I want to build a strut brace but keep changing the design, what ever way it goes I need to start at the spring turrets so had these made to get things under way.





Other news, the steering rack is back in with the new bushes, not very interesting so no pictures.

Great car and love the updates. My 820 Vitesse is coming along nicely too and I was wondering if you would sell me you old ss exhaust if its now surplus to requirements? (mine is blowing) i'm only in Fetcham, Surrey so just down the road from you. Thanks Ben

Found some perfect size brass bushes to replace the old worn plastic gear linkage bushes, so perfect it has no freeplay and operates like its fitted with ball bearings. With the extra bit of gear lever throw from the reduced short shift mod it feels much better.



Cleaned, painted and back together







The cooling fan deserved a clean and paint while it was out.
This is a spare but it shows the fibreglass heat shield and how the surface deteriorates after 20 odd years.



Cleaned and painted, with a few extra holes in the cowling



and with the cover tidied up and painted, fitted with chrome nuts



The new downpipe runs close to the water pump and a slightly re-routed bottom hose so I fitted another little aluminium heat shield