HC5A Kart build

[ausjet]

Gday gents, I'm Keith from Perth, Western Australia. I've been a member for a while, mostly spend the time that I have on this site learning about and admiring everyones creations. About 5 years ago I made my first turbo based gas turbine, based off RC Don's stuff, running off a BBQ gas bottle.  It worked.. EGT was a bit high, but it made some noise, pissed off some neighbours and didn't destroy itself, so was pretty happy !





I thought i'd start a build thread about my current jet kart project. I bought this turbo (pictured below) quite some time ago and have been collecting parts for years although never had the time to get anything done.  I would love to build a freepower turbine for it, but i don't have access to a lathe or mill, so after I get it running, I’ll need to make an afterburner!



Specs:

Holset HC5A

Compressor: 98/141mm

Turbine wheel: 129/111mm G trim

Turbine housing is a "41cm" not sure if this is something to do with the A/R



I used jetspecs for a guide on dimensions then tried to find the closest readily available material.

Flame tube length: 490mm (19.2”) with a 20mm airgap between it and combustor

Flame tube diameter: 177mm (7”)

Combustor diameter: 228mm (9”)

Kart is an Arrow AX9, senior chassis, I will be using a spray nozzle and diesel fuel for the combustor. Would like to keep it simple and reliable.

Heres what I've done so far.

[ausjet]

Combustor is an air tank. Once I cut it open I found areas inside that needed heaps of grinding. I hope you don't mind, I took some inspiration off your 6041 kart John/Smithy with the V-band arrangement.  I had a local heavy duty exhaust shop machine/set it up for me.



Pressure testing the combustion chamber. A stiff breeze would blow straight through the v-band clamp seal area. I assumed when the exhaust shop made it, It would be air tight..wrong! woops. 1 V insert has been lathed, the other, bent or pressed.. this is the part which isn't completely flat. I managed to get it to seal a fair bit better with a different larger style of v-band clamp but still leaks.  Does anyone have any tips on sealing these? could i use a thin silicone or similar gasket?


 Variflo bypass adaptor and nozzle


Testing the nozzle fitment

[stoffe64]

Interesting build,is that turbo a Holset or is it such China copy?
It should produce plenty of thrust!!
Cheers/stephan

[ausjet]

I hope it's not China copy, I was told it's a genuine reman holset. It was originally built for tractor pulling.

[smithy1]

G'day Kieth....loving the project....and nice looking turbo, 98mm inducer is not a lot smaller than the GT6041...so with a good A/B you'll be making a decent amount of thrust, I suspect something approaching 180-190lbs-f.

Here's a pic of the GT6041 beast as it sits today:



The kart chassis I believe is an old mid ~'90s "Stockman" but that's all I know about it.

At full noise and full Afterburn....John and I believe she should be good for well over 200kmh, given enough room of course..!

Do you have any info on your fuel injector?? I'm in the market for one myself.

For sealing the V band, you may be able to use a large diameter small section "O" ring..?? 

I'll be following your thread with interest.

Cheers,
Smithy.

[stoffe64]

Hello Keith!
I am sure that this engine will Scream with ALOT of thrust,i will also follow this build with great interest....i really would want to build something similar in Size,instead i have to be satisfied with a "small" HOLSET HX60
Cheers/Stephan

[ausjet]

May 29, 2017 17:34:51 GMT -5 smithy1 said:

G'day Kieth....loving the project....and nice looking turbo, 98mm inducer is not a lot smaller than the GT6041...so with a good A/B you'll be making a decent amount of thrust, I suspect something approaching 180-190lbs-f.

Here's a pic of the GT6041 beast as it sits today:



The kart chassis I believe is an old mid ~'90s "Stockman" but that's all I know about it.

At full noise and full Afterburn....John and I believe she should be good for well over 200kmh, given enough room of course..!

Do you have any info on your fuel injector?? I'm in the market for one myself.

For sealing the V band, you may be able to use a large diameter small section "O" ring..?? 

I'll be following your thread with interest.

Cheers,
Smithy.

Hey mate, thanks! it's a monarch bypass nozzle. 60 degree, have a few to try, a 15.5gph (bypass closed @100psi) and a 17.5gph. The bypass nozzles need their own adaptor, got it all off eBay. I havnt tested them yet so not sure what pressures I'll need to run. I would like to try and use the bypass as a throttle. Will do some testing at a later stage to see if that will work

[Deleted]

Hi Keith, real nice looking project.... look forward to seeing it progress

Have used v bands on two of my engines ( pictures below ) I found if you could make some kind of slip joint ( or step ) between the two half's it helps with sealing, and as a sealer i used www.halfords.com/workshop-tools/garage-equipment/head-gasket-exhaust-repairs/loctite-5990-premium-silicone-copper-gasket-maker-sealant ,





You can see V band clamp at the bottom of C/C



This engine had the V band in the body of the C/C with a slip joint





I would look at a nozzle with a 80 degree spray, semi solid pattern. and at least 17 us/ghp perhaps even 19

Hope its some help

All the best Andy

[smithy1]

May 29, 2017 23:45:23 GMT -5 andym said:

I would look at a nozzle with a 80 degree spray, semi solid pattern. and at least 17 us/ghp perhaps even 19

Hope its some help

All the best Andy

G'day Andy,

Would you happen to have a link to these fuel nozzles please Sir??

Cheers,
Smithy.

[stoffe64]

Hello Smithy!
Go to danfoss homepage
Look. For oil burner nozzles
Cheers /stephan

[Deleted]

Jun 1, 2017 20:21:32 GMT -5 stoffe64 said:

Hello Smithy!
Go to danfoss homepage
Look. For oil burner nozzles
Cheers /stephan

Hi Smithy

there is lost of info out there, but here are a few links people mite find helpful


Monarch nozzle 17.5 us gph with 80 degree "PLP" from memory is there semi solid pattern

www.partscenter.co.uk/product/monarch-175-x-80-plp-nozzle/

Delavan and Danfoss have other codes for there patterns, this link is to a section of nozzles

www.partscenter.co.uk/webapp/wcs/stores/servlet/CategoryDisplay?storeId=10202&catalogId=10052&langId=44&categoryId=96178&pageView=detailed&pageSize=24&sortColumn=score&sortType=desc&seoURL=0

This link is pdf from Danfoss site, tells you alittle about there range

heating.danfoss.com/PCMPDF/DKBGPG060A802.pdf

I could post lots more links, but depending on where you are in the world, will depend where you can order from.... heating company's etc. The manufactures dont like dealing with the public, and just tell you to deal with agents, but then you got to find an agent that has bigger nozzle sizes in depending on your needs, Danfoss go up to 25 us gph in a 80 semi solid, and 50 us gph 80 semi solid in the bypass stile nozzle. The problem is, i was once told "most of the agents have to order 10 units a time of one size, and tend to carry only popular smaller sizes". I got lucky over here and found a guy with contacts that could get the larger sizes, and he thought what we did was bonkers and loved it :-)

This web site mite be worth a look and email to ask about larger nozzle size

www.heating-parts.co.uk/Burners/catalogue/165/

or this site

www.heatingpartscenter.co.uk/burner-spares-and-accessories/oil-nozzles

Help its some help
All the best
Andy

[smithy1]

Cheers Andy....that's a great help...thankyou..

Smithy.

[ausjet]

Was able to seal the combustion chamber v band 100% now, used a thin high density foam as a gasket. Have started working on the combustion liner.

Thanks Andy, I was able to get my hands on a 15.5 and 20gph 80 degree BPS nozzle. Does anyone have some advice on placement of the primary holes please. I'm planning to make a swirler for the domed section aswell. I have tested the 80 degree spray nozzles with water at 100psi to see where the spray hits the FT wall. Its about 150mm down- which seems quite far down.. (marked with the chalk in the picture) I had a bit of a guess as to hole pattern and placement
primary:
1st row 12x10mm
2nd row 24x6mm
3rd row 6x9mm

Secondary:
8x14mm

Dilution:
6x24mm

[racket]

Hi Keith

If you have 10% - 750 sq mms of swirler area surrounding the fuel nozzle , then you only need ~1500 sq mms of Primary wall holes , otherwise you are going to be running a pretty lean Primary Zone at ~38%.

I'd be going for less number of Primary holes , its a big flametube diameter , maybe 8 holes at 14 mm dia ( 1230 sq mms) , 100 mm downstream from the spray nozzle outlet assuming its level with the dome of the flametube cap , use the remaining 300 sq mms for some small 2 mm dia wall cooling holes at say 70 mm and 130 mm down from the nozzle.

As you're using a billet comp , your rpm can eventually be getting closer to 70,000 rather than 60,000 , thats a performance turbo , don't "neglect" its potential ;-)

Cheers
John

[ausjet]

Thanks John, have updated the design. Is it ok having the secondary holes the same diameter as primary?