Since my car is up and running decent I figured I would post some pictures of the process. Before finding this site I didn't know a single thing about turbos or tuning. That was only ~5 months ago.
This build is about as cookie cutter as it gets. I don't have much fab experience so I wanted parts that I knew would fit without too much fiddling.
First thing I bought was a Rev MS2 Basic, it does everything I need to to do. I'm sure some will say I should have held out for a MS3 but mreh.
I made this ugly bracket to hold it. Obviously I don't do much fab work. Put foam on the inside so it doesn't rattle or scratch the MS.
I ripped a wiring harness out of a junkyard car and used it to wire the IAT and extend the wideband wiring.
I also ended up using it to wire new grounds for the TPS and CLT since they were giving BS readings. Reverent helped with the diagnosis which helped a ton.
Temporary wideband mounting.. I knew I had a dual pod on order with the FM kit so I didn't bother doing anything fancy.
Here's where I originally mounted the IAT. I spent a solid hour making this nice PVC bung that I drilled and tapped for the sensor. It ended up being a TERRIBLE
idea. It would heatsoak very quickly. Eventually I put the IAT over by the airbox, inside the fender intake tube, which worked marginally better.
and mounted it in a blank off plate on the passenger side. I have a serial to USB adapter on the end of the MS which runs up the center console to the mounted port. Also bought a flat 3.5mm cable to tidy up the aux port for my zune.
Late night idle tuning. Kind of a cool picture.
My FM kit arrived but I didn't really have the time to install it yet. Hooked up the boost gauge and installed the dual pod in the meantime. I think I installed my injectors sometime around here as well.
ooo it glows red
Finally got some time to install it. Took about 5 "days" to installed (I worked until about 3pm, then would work on the car til about 10pm).
Jack 'er up
intake things off..
Broke most of these heatsheild bolts. Even after soaking them in Aerokroil for 2ish hours.
I ground this down so you can remove it without fussing with that bottom bolt. I forget where I saw this originally but it's a great idea.
I had to grind off both the downpipe to cat bolts. This ended up taking the majority of the first day because I couldn't fit the big grinder in there. Had to use the pneumatic one which would only grind for about a minute before the compressor had to run.
Wait.. aren't these supposed to be nuts? great!
This is about how I felt after the first day. Damn northeast cars and their rusty exhaust.
So here's where the cringe worthy stuff starts. My car is an R-titled car and was smashed in the front at some point. There was a crease in the frame rail, which lined up perfectly with where FM suggests you slot the frame. I ended up going a bit overboard and notching about 1/2" into the frame and welding it back up. Overkill but everything fits now.
And then while drilling the oil drain hole, the bit walked (a lot). You can see the line where the middle should be. Probably walked a solid 3/8"
At this point I nearly ripped out the AC, since I hadn't got it working with the MS yet, I figured what's the difference. I took a second look at everything and realized I could probably get away with just notching out the AC bracket..
Pretty sure I just took these next two so I could see if I had everything lined up right. But here they are anyway. Oil feed under the intake side, using FMs tee and feed line.
I started working a bit faster, so there aren't as many pictures. But here's the turbo and plumbing.
Broke both hood latch bolts while mounting the intercooler. Had to take off the bumper to drill and tap them. Should have just taken the bumper off in the first place, though. I ended up scratching it pretty well.
Downpipe mounted (to stock exhuast lolol)
BOV and intercooler piping done.
Water lines and intercooler to compressor piping.. damn that's tight.
Really tight. I'm going to keep and eye on this.
First start.. Success!!
A bit of a leak from the top radiator hose. But oil and the turbo water lines were fine.
So that was thursday night. Friday I put the bumper back on and trimmed up the rad mouth and splash pans. Took it out for a initial test drive and holy ****! It's only running wastegate pressure (5-6psi) but it feels great. It was running quite rich in boost, about 10.5-11.0 initially so I pulled some fuel and got it to a more reasonable 11.3-11.5 and obviously still tuning it from there (11.8 target)
So the plans from here are:
Radiator - Not sure how temps will hold up, they've been fine so far but it's also been pretty cool outside.
New clutch - it holds fine under boost, but it'll slip with quick gear changes.
Exhaust - Probably a Artech or Enthuzacar piece.
Wastegate port? I've heard of boost creep problems on the 2560 and a larger exhaust. We'll see.
In that order.