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XJ40 Turbodiesel

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 15, 2021 11:40 am

With that all fitting I welded those up completely so any warpage would be taken account of later (didn't notice any, luckily enough).

From there I switched tactics for the over-axle pipes. This was by far the most complicated part of the design, but didn't turn out to be quite as difficult as I was imagining. With bits of chopped up silicone hose to sort clearances, cable ties to hold things in position, and much fettling with various bends and lengths I managed to get it to fit. Clearance is tight, and the pipe is in contact with the crossmember that runs over the top of the axle tunnel so that'll need the axle dropping to cut that back for clearance, but it does actually fit!

In the order of the photos you can see it heading back from the rear of the car, up over the axle, and down the front to meet up with the centre pipe at another v-band.
Attachments
Exhaust 9.jpg
Exhaust 9.jpg (169.21 KiB) Not viewed yet
Exhaust 11.jpg
Exhaust 11.jpg (164.1 KiB) Not viewed yet
Exhaust 12.jpg
Exhaust 12.jpg (173.31 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

katar83
Posts: 3068
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 Turbodiesel

Postby katar83 » Fri Oct 15, 2021 12:43 pm

Some great work here, I'm tempted to get a TIG as well but use my trusty Clarke so far and it never let me down. I'm not sure I'm seeing it right but have you got any exhaust boxes in there or is it straight through pipe all the way to rear back boxes? :lol: Personally, as much as I like 'throaty' exhaust I absolutely hate it when its loud in the cabin itself and it would just annoy me on a longer run. With your resto I'd go as far as stripping everything inside down and covering everything with soundproof mats.
Also, I hope you got your shapes right going over the rear frame, there is so little space in there that I've struggled even welding original pipes there myself without something rubbing on them, especially with the car on the ground and going over bumps :roll:
1996, 3.2 SWB X300 - Relatively rust free daily driver!
1997, 4.0 LWB X300 - Unlucky car, sold 10.2020!.
1988, 3.6S XJS - Never ending restoration project.
1994, 3.2S X300 - Accident damaged, 10.2015. Gone!
1994, 3.2S XJ40 - First Jaaaag, long gone.

Wilfred88
Posts: 259
Joined: Mon Jun 23, 2014 11:05 am

Re: XJ40 Turbodiesel

Postby Wilfred88 » Tue Oct 19, 2021 2:54 pm

nicely done! clever to use the hose as spacers

I am currently working on another conversion project. Subaru engine in a volkswagen baywindow, and with the exhaust I was wondering how much clearance is enough ro prevent the nearby surfaces from getting too hot.

for some critical parts, I wrapped the exhaust with exhaust insulation. THat fiberglas isolation tape stuff. Makes all the difference I've noticed.

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 22, 2021 11:20 am

Thanks guys!

Yeah same. We've got an old SIP Ideal 150 where all the controls are in Italian. 'Velocita Filo' means 'wire speed' :D it's welded everything I've tried to weld with it (apart from that one time I was accidentally trying to weld steel to brass...).

I'm of a similar opinion that I like a throaty exhaust but not so much the boom. I'm a big fan of the exhaust cutout valves my mate has on his V8 E36. You can have nice sedate cruising and then rip-snorting noise at the press of a button. But on these modern turbodiesels the variable vane turbos do a lot of silencing on their own. You can stick a straight pipe right on the back and it still won't be terribly loud (I'm not having any silencers at all! Just a pair of resonators at the back). I'll assess how the cabin noise is when cruising and if it's too much I'll add another resonator to the centre pipe. You can measure the frequencies that are too loud and do some whizzy calculations to find out what volume of resonator you'd need to cancel them out.

Oh, and there is an element of trying to combat some of the diesely clatter from the engine. These M57s really aren't that bad (especially compared to my clattery old Citroen BX!), but they're no AJ6 (and that's no 1UZ, sdly). A little white noise from the exhaust would go a long way to making that less noticeable.

You and me both on the clanging exhausts. My old silencer substitute pipes used to do that and it drove me mad :D I'm hoping that with a bit of relieving of the chassis and some really solid location it shouldn't move around too much.

And yeah, I wasn't sure how much space you'd need around the exhaust either. I've used the Jag triangle centre mounts throughout which seem to hold it really snug, but there are some bits where it's close to the underseal. I'm hoping that because those bits are at the back the gases should have cooled significantly by then, but if not I'll definitely look at that fibreglass wrap! Love the idea of a Subaru engine in a bay window! Are you using the Subaru 'box or the VW one? I remember looking into a company in the states that did reverse crown wheels and pinions for Subaru gearboxes so people could put them in Beetles. There was even a guy who made a rear-engined AWD Baja Bug with one of those and a flipped over R160 in the front.
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 22, 2021 11:25 am

Speaking of rear resonators, that was next on the list. Similar story of chopping out little bits and pieces and propping bits up with cable ties and shims. I completely eyeballed the size of the resonators, so we'll have to see how effective these are. They're mainly there to try and cut the tinny noise you can get from stainless straight through systems.

At this point I figured I should take the rear coilover out and test the wishbone through its full range of movement. Turns out it contacted the pipe just as it tickles the bump stop. As there's a fair bit of compression in the bumpstop I chopped it up and fettled a bit more until it was higher.
Attachments
Exhaust 2 1.jpg
Exhaust 2 1.jpg (126.94 KiB) Not viewed yet
Exhaust 2 2.jpg
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Exhaust 2 3.jpg
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Exhaust 2 4.jpg
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Exhaust 2 5.jpg
Exhaust 2 5.jpg (189.25 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 22, 2021 11:32 am

That was all the actual pipework together, so all that was left was mounts. The rearmost one was simple (although I did do this after all the other ones were sorted). Just wedge the tailpipe in the right position, tack it in place on the car and then weld fully.

To try and stop everything from moving around I used one of the Jag centre mount rubbers on the side as well, through 90 degrees from the centre one to provide a bit of triangulation. Started with some 20x50 box section, cut it to shape, bent the little mounting tabs so they fit in the half-moon-shaped holes snugly, and that was one mount ready to go on the car.
Attachments
Exhaust 2 6.jpg
Exhaust 2 6.jpg (231.88 KiB) Not viewed yet
Exhaust 2 7.jpg
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Exhaust 2 8.jpg
Exhaust 2 8.jpg (116.3 KiB) Not viewed yet
Exhaust 2 9.jpg
Exhaust 2 9.jpg (134.57 KiB) Not viewed yet
Exhaust 2 10.jpg
Exhaust 2 10.jpg (129.17 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 22, 2021 11:41 am

Luckily there's a little recess underneath the rear chassis rail that the mount tucks snugly into. Welded that onto the car, then made up some tube to connect to the exhaust pipe (think it's 16mm diameter, but can't quite remember!). Gave it a wiggle and it's rock solid back there. Hopefully the flexi section up front will take up any engine movement, although if I see signs of cracking I might have to add a second somewhere.

Then just had to do it all again for the other side! :D
Attachments
Exhaust 2 11.jpg
Exhaust 2 11.jpg (173.42 KiB) Not viewed yet
Exhaust 2 12.jpg
Exhaust 2 12.jpg (179.21 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Wed Nov 03, 2021 10:17 pm

It was around this time that I got a call that the propshaft was ready. The folks up at JW Engineering in Bexleyheath chopped up the 330d prop, an E46 320i midsection (for the splined bit), and a Jag yoke to make something that fits. Fair bit of work went into stepping up and down the 3" tubes, which put the price up to £390, but I got the impression a simpler prop would be much more affordable.

Also, as luck would have it the 320i centre bearing has the same 30mm ID as the XJ40 one. I'm hoping the 30mm diameter is enough to hold up to the torque. The 330d one had a 35mm centre bearing, so I plan to add a prop check strap just in case it lets go at any point. I did also have to very carefully cut off some of the dust shield so it would clear the BMW centre UJ, but it fit slipped on perfectly as it's both the same ID and width as the bearing I have (I've read elsewhere that there's a 42mm centre bearing around somewhere as well, but as far as I can tell the one I have on the prop that came off the car is 30mm).
Attachments
Propshaft 1.jpg
Propshaft 1.jpg (425.35 KiB) Not viewed yet
Propshaft 2.jpg
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Propshaft 3.jpg
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Propshaft 4.jpg
Propshaft 4.jpg (161.37 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 153
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Wed Nov 03, 2021 10:21 pm

Took quite a bit of fettling to get it into the car. My length measurements were pretty good, but I think I was planning on using the BMW centre bearing which is a lot shorter than the Jag one so I had to shim the gearbox mount up by about 8mm to get the twist out of the propshaft doughnut. I also managed to just miss the stock mounting holes :D

Lastly I had to bend the handbrake lever arm down a fair bit to put a bit of distance between the cables and the prop, otherwise it would clang against it as I'm driving along :D You can still get it to touch, but you have to push up quite hard so hopefully it won't really see that amount of force in normal driving. Really a 2.5" section at the back would have been advisable (the back section is much shorter, so could have been thinner).
Attachments
Propshaft 5.jpg
Propshaft 5.jpg (193.37 KiB) Not viewed yet
Propshaft 6.jpg
Propshaft 6.jpg (158.74 KiB) Not viewed yet
Propshaft 7.jpg
Propshaft 7.jpg (153.53 KiB) Not viewed yet
Propshaft 8.jpg
Propshaft 8.jpg (138.06 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

katar83
Posts: 3068
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 Turbodiesel

Postby katar83 » Wed Nov 03, 2021 11:18 pm

How are you planning to set this up if at all? It's generally an absolute ball ache to get the Jag prop set up correctly and if it's not done right you'll always get shakiness at certain speeds.
No idea if it's going to be similar here?
1996, 3.2 SWB X300 - Relatively rust free daily driver!
1997, 4.0 LWB X300 - Unlucky car, sold 10.2020!.
1988, 3.6S XJS - Never ending restoration project.
1994, 3.2S X300 - Accident damaged, 10.2015. Gone!
1994, 3.2S XJ40 - First Jaaaag, long gone.


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