Zork fitment issues

[jsveb]

Hi

I recently had a chance to purchase a Zork and WG pipe.

Today after having the O2 bung welded locally (I wish they had the same standard as RarlyL8 has), it waas time to put it on, so I can finish some of my other project on this car.
The Zork fits nicely, but I simply cannot make the WG pipe sit properly beside it. Where they turn about 90 degrees the bump into each other. I have tried for quite a while to see what I did wrong.

My car is a 1978 930 with some mods K27, ANDIAL IC etc. I think the turbo mount is stick, but you can maybe help ID that as well.

What to do???

Here are some pictures:





What am I doing wrong?

[cole930]

Jesper it looks like you have a slip joint in the middle of the waste gate pipe near where the pipe crosses in front of the turbo. Can you pull it apart there and trim off the male end enough to give you a shorter distance to the
90*bend.

Cole

[infraredcalvin]

Originally Posted by cole930

Jesper it looks like you have a slip joint in the middle of the waste gate pipe near where the pipe crosses in front of the turbo. Can you pull it apart there and trim off the male end enough to give you a shorter distance to the
90*bend.

Cole

+1

Also verify that then end piece with the 90 bend is fully inserted into he slip joint. If you talk to Brian, he'll tell you that the waste gate pipe will be a custom fit piece due to slight variances that are exaggerated with the length of the pipes.

[jsveb]

Thank you guys

I tried to wiggle the WG in the slip fitting all I could. Thought it might be necessary to do some cutting.

There are two holes in the WG pipe, one on the male and one on the female. I thought maybe by ligning these up, it should fit on a stock setting. The pipe is fully joined and ligned up (the holes) in the picture.

[RarlyL8]

There are a couple of things I see.
A clamp has been added about 6" from the WG flange; that pipe is supposed to be one piece. The 934 WG pipe shown was designed to use with the OEM J-pipe exhaust so no cutting is needed. If a section was cut out it will angle the tailpipe away from the zork. Was this pipe modified to fit headers or a turbo who's exhaust housing was not in the OEM position?
There is one slip joint to allow lateral movement and ease of assembly. The tab slips over the bottom turbo stud as shown in your picture. The assembly all slides together and bolts in place at the same time; zork, WG tailpipe, and WG flange pipe.
Two things to check.
Remove the zork and bolt the WG pipe on. It is important to tighten the 12mm WG bolts as the pipe will move quite a bit if loose. Verify you have enough lateral movement to fit the tab on the turbo stud and over the zork flange and gasket (~3/8").
Remove the WG pipe assembly and bolt up the zork. Bolt the WG tailpipe only in place and verify the mounting tab locates the tailpipe as it should. Slide the WG flange pipe loosly onto the WG and verify the angle at the tailpipe slip joint is suitable for the two sections to join.
This system has quite a bit of flexibility, however the placement of the turbo is critical for the angles to line up. If the turbo exhaust outlet is not in the OEM position the tab will not line up. The tab can be bent and the slip joint moved for use with 3LDZ or K27.

[930LDR]

I for one ran into turbo placement issues when I installed Brian's zork and wg pipe. When you look at the turbo mount on my car you can see that who ever originally upgraded to a K27 did some sort of mickey mouse fabrication to contort the mounting plate to fit the bigger turbo.

[jsveb]

RarlyL8, thanks for helping. The clamp in the picture is just hanging there. The Pipe has not been cut. The only joint is the slip joint as you mention yourself. I must say the quality of your product is outstanding. There are drilled two holes in the slip joint. When I line these up it seems that the WG pipe sits properly (if only I could make it fit all together).
This leads me to two conclusions:

1. I cannot do the job (it seems quite simply...)
2. My turbo is not in the correct position.

I will try your fitting method and report back, but first I want to put my injectors back in. I found some copper washers at a Diesel shop in town.

[jsveb]

Originally Posted by 930LDR

I for one ran into turbo placement issues when I installed Brian's zork and wg pipe. When you look at the turbo mount on my car you can see that who ever originally upgraded to a K27 did some sort of mickey mouse fabrication to contort the mounting plate to fit the bigger turbo.

Please don't use the term Mickey Mouse in relation with my car again

Seriously, would you be a little more specific. This is my first 930. Haven't seen it any other way.

thanks

[RarlyL8]

I have pictures of the installation process on another computer and can post later if helpful.

[BlkBird]

Interested to see how this turns out.

Can the O2 sensor be placed that close to the turbo outlet? Are you planning on placing a heat shield between the O2 sensor and the Zork tube?

[jsveb]

I have pictures of the installation process on another computer and can post later if helpful.

I would appreciate that.

Yes, I have made a heat shield.

[RarlyL8]

If the WG flange pipe has not been cut you should be in good shape. The WG tailpipe should rotate up and down to "screw" into the female flange pipe slip joint. As you do this the tab will rotate onto the turbo stud and the zork tube will butt up to the gasket/turbo. All should move into place. The WG flange pipe should be tightly bolted to the WG before you do this.

[jsveb]

And some determination...

I think my turbo is a bit off to the left, but I made it fit.

Rarly, I followed your advice and did it.

[Ronnie's.930]

I like it !!!!

[jsveb]

Nice.

I think I might have some issues with the valance I bought since it was used. I think to cut is off for my aplication, but I'll make it work

What Aerosol should I use to paint the Fibreglass?

[JWLindsey]

Dang Jesper. Sorry it took so much work to fit it up. I see you have the same expert help I have so perhaps the valence mods will go quickly!

-JWL

[jsveb]

Originally Posted by JWLindsey

Dang Jesper. Sorry it took so much work to fit it up. I see you have the same expert help I have so perhaps the valence mods will go quickly!

-JWL

No worries. It is all fun - in good company.

I think it is my turbo and not the Zork I bought from you that is off. It looks great. I also think it is a good thing that I always carry earplugs when going to work

[Ronnie's.930]

"What Aerosol should I use to paint the Fibreglass?" - QUOTE

I used PPG single stage urethane over urethane primer. . . I also covered the inside of the valance with aluminum tape . . .

BTW, mine is not a Zork, but a Zork look-alike (Brian's center exit muffler package) - not as loud . . . The unmuffled, wastegate pipe sounds great under bridges etc. - makes me feel like a teenager again !!!

[Ronnie's.930]

View from the top:

[jsveb]

Originally Posted by Ronnie's.930

"What Aerosol should I use to paint the Fibreglass?" - QUOTE

I used PPG single stage urethane over urethane primer. . . I also covered the inside of the valance with aluminum tape . . .

BTW, mine is not a Zork, but a Zork look-alike (Brian's center exit muffler package) - not as loud . . . The unmuffled, wastegate pipe sounds great under bridges etc. - makes me feel like a teenager again !!!

PPG, I cant get that in a rattle can, can I. All my (most of them) shop tools are back in Denmark, So I am somewhat limited in operation.

I noticed the band around your exhaust and WG. I have only heard of Rarly's center out muffler never seen it. As I said - NICE.