Winter is coming and I still spend my time at the engine compartment and under the car. Maybe I have been a bit lazy.

I purchased a pressure switch and pop-off valve for the turbo. The switch operates if something goes wrong and the boost pressure rises too much. The ignition is then shut off. The pop-off valve makes the life of the turbo and its hoses a little bit easier. The valve comes open and lets the boost pressure out of the plenum when the butterflies of carburetors are shut suddenly, so preventing the high-pressure spike that would occur otherwise. That kind of situation occurs, for example, when shifting gears during acceleration and the turbo spins fast.

The next task was to construct some copper gaskets. Although I used annealed 2mm (0.8") copper plate which was quite soft, the job was huge. If these copper gaskets give good results and I decide to use them in the future, I'll get them made using water cutter.

The wastegate was finished and fitted to exhaust manifold with the turbo. It looks strange, but it seems to work when a small pressure is led to the actuator for testing. The gate was pre-set to open at 0.5bar, which should be enough for the 1100cc engine. At least, the gate seems very easy to set.

The intake manifold was coated with Thermo-Tec. This prevents the intake manifold for heating despite of being so close to the exhaust manifold. The coating was not applied to the exhaust since it would create heat stress cracks on mild steel.

Picture 40 presents the situation where the both manifolds are in the engine compartment and the head is also in the place. The copper gaskets were annealed prior the installation. Those were put in place with some silicone-based high-temperature resistant sealant to prevent any leaks. With the head gasket, the compound was used only in the vicinity of coolant and oil passages.

There were huge problems with fitting the manifolds since the turbo and the wastegate were on the way and the fasteners were not reached easily. My hands were full of scratches after the installation. The water pump and its line were also fitted. The latter needed some hammering to free some space for the wastegate. Its exhaust outlet is not led anywhere from the compartment!

Hopefully the joints of the manifolds and the turbo are leak-free. Well, it is seen when the engine is started for the first time.

The carburetors and hoses were fitted next. Those were an easy task compared to the manifolds, for example.

The engine looks more ready in the picture 41a. Some asbestos plate is still needed to protect the carbs from the heat of the exhaust manifold.

The exhaust tailpipe had to be built next. Picture 41b presents the pipe used on the first test ride in wholeness. :-) The assembly contains also a support bracket for the exhaust and the turbo that is bolted to the block near to the oil sump. Otherwise, the manifold would not stand the weight of the turbo. Hopefully those won't heat the sump and its gasket too much.

Since the turbo is located very close to some other parts, it was decided to equip with some heat shields shown in pictures 41b and 42. The first picture presents the heat shield of the turbo, which hopefully reduces heat radiation. The second picture shows some aluminum plates that are used to protect the alternator and the steering gear. The exhaust pipe shown above got some heat wrap, because it is located close to driveshaft and some other components.