Left Handed Elvis

This is all the fault of a white '92 1.6 turbo'd in Baltimore maryland with a Greddy/Stillen kit in 1994. Loved it then, so of course I need to do it myself.

So here is the base line: 94 1.8 A-package car, manual windows, 5 speed, 103k on the clock, original one owner car

Current state of tune is stock, car has Flyin-Miata V-maxx 2 kit with sway bars, has a Hard Dog Roll bar on order and a Momo steering wheel, new timing belt, mishimoto 3 core radiator with stock fans - CAT back exhaust is likely going on the car soon as well

The plan is as follows:

Steps in this order:
MTX-L Wideband
MSPNP2
Re-manufactured RX8 injectors
TD04 off a 2006 WRX with 30k miles on it (yes I know it is less than ideal but a FREE, factory built, low mile TD04 is better than a china charger made out of recycled Budweiser cans IMHO)
Fleabay cast iron manifold with Chinese cast iron Garrett T25 to TD04 adapter - this way in the future I can go T2560 or something like this without having to reinvent the turbine wheel **if cast iron adapter is not good enough (as it look a little sketchy) at least it will be a useful CAD template @$40 and I'll make it out of a mild steel plate
CX Racing intercooler kit
Turbosmart manual boost controller

Will start with stock boost - whatever factory boost (7psi?) is set for from TD04 get it tuned with MSPNP use the over boost control to keep it safe but gradually increase the boost and hoping eventually for 10-12 psi.

I am hoping for 170 whp. Mighty Car Mods using the exact same turbo got 196whp using a fabricated log style manifold (better flow is my guess) and a Halltech system running 12psi so I think this is reasonable.

Total budget is $2000 and I would like to at least get the uprated clutch/flywheel parts into the mix if at all possible even though that might blow the budget

Here are the questions:

1. I am a little leery of the cut to fit nature of the CX racing kit universal nature. I can afford to get a better kit but wondering if I cut it to fit and get it bead rolled, should I be ok? The more expensive options are another couple hundred in parts....
2. As far as intercooler size goes, I would like to go as large as possible and since the Mishimoto is MASSIVE I think I can obstruct a little more airflow with the bigger cooler - which will help with the smaller turbo higher boost heat sinking... am I right or wrong?
3. As far as clutch/flywheel goes there are a LOT of options but are there lesser cost but still strong enough options other than things like the Flyin Miata "Happy Meal" kits at $600? How much clutch do I need for the hoped for 200whp? Brand names that work for you?
4. I have a used flange from the same model Subaru the turbo came off of to use as a base flange for the down pipe or as a template for a new flange - what grade/thickness of steel do I need to use so that it will not crack?

I would like to get comments toward the sanity of the plan and anything that you all might feel that helps. Anyone running a TD04 that has real world experience with this specific turbo would be greatly appreciated.

Cheers for the help.

guttedmiata

When we first started racing our car it had a greddy kit with the td04. We pieced together mandrel bent piping to eliminate the restrictions in the greddy piping and the eventually bought an eBay stainless manifold and then made our own adapter to mate an eBay 2.5" downpipe and very free flowing exhaust. Car was good for about 215hp at 12psi. This was just running a bipes piggyback. This was also a 1.6.

i don't know the details of the td04 on the Subaru, but way back, we were running 22psi on a td04 from a Mitsubishi. It's a stout little turbo.

we have gone to a 949 supermiata race twin clutch. The FM happymeal we took out is around somewhere. I'll make you a deal if you're interested.

hi_im_sean

iTrader: (3)

https://www.miataturbo.net/build-thr...ru-td04-74776/

post #1344 for dyno numbers and possible limitations of this turbo (still troubleshooting)

hi_im_sean

iTrader: (3)

Also, get the GT500 injectors and skip the RX-8s. Thyre about the same price(if you know where to get them, or less if you are rebuilding and flowing the rx8s), flow more, and are newer technology.

DNMakinson

iTrader: (3)

Deal from Gutted might be a good way to go. Otherwise, consider the FM 1 clutch and reface your flywheel.
Add your location to your profile.
Pretty sure my TD04 is from a 2005, and so may be slightly different. It is a 13T compressor. Would work fine for your goals.
No need for massive intercooler for your goals.

You our can see my build thread. Likely you will make your power goal with wastegate only.

Braineack

iTrader: (62)

The greddy turbo was a 15g. The wrx is a 13t, going to spool much faster.

Left Handed Elvis

Thanks for that recommendation, are the Gt500 injectors plug and play?

hi_im_sean

iTrader: (3)

They are not, but you can buy the pieces to adapt them pretty cheaply.

Left Handed Elvis

Yes iam interested in the FM happy meal. Will it fit a1.8? How much? Miles on it? Flywheel weight? Please pm me the details when you get a minute.

Braineack

iTrader: (62)

FM only makes 1.8L clutches.

you only need the "Happy Meal" if you have a 1.6L or really want a lightweight flywheel.


you could go to flyinmiata.com and find out all this information for yourself; i know that's a huge thing to ask of someone...

Left Handed Elvis

Well, seeing as the original poster offered he was running a TD04 on a 1.6, I am building a 1.8 I thought CLARITY was prudent. (FM used to offer Happy Meal clutch kits for 1.6 cars and still does....) What I was looking for was since theHappy Meal is listed as NA/NB for the 90-93 and the 94-97, I wanted to be sure. Sorry if I asked a stupid question...I did not realize the clutch Happy Meal was the same for many years.

Braineack

iTrader: (62)

you cant buy a 1.6L sized clutch from FM; they dont make one.

BUT you can buy the happy meal and get a 1.8L sized flywheel, then utilize the 1.8L sized clutch.

the FM clutch is great.

Left Handed Elvis

Cheers Senor B. Oh, and I do want a lightened flywheel for response. I had an RX7 with a light weight flywheel and LOVED it.

Left Handed Elvis

Anyone have any thoughts in intercooler size?

shuiend

iTrader: (24)

Buy one and call it a day. A bit more expensive then the eBay ones, but the quality difference between the eBay and that one make the cost worth it.

Left Handed Elvis

Thanks I'll take a look.

shuiend

iTrader: (24)

It is the same core that Fab9 uses for his intercoolers.

Left Handed Elvis

Sweet thank you for the details. I also found a Mishimoto that is shorter and not as thick for about the same price. I've searched Miata Turbo but have yet to see anything that clearly explains intercooler sizing. Since I am looking at TD04 and running (probably) no more than 12psi of boost, how do I know if one is better than the other? I mean it may sound like a totally moronic question but can you have too big of an intercooler? Other than the constraints of the space it fits in, I mean?

Left Handed Elvis

These are the specs for the Mishimoto offered at $168:

• Six threaded mounting points for universal fitment
• Overall Size: 28" x 7.5" x 2.5" / Core Size: 20.5" x 6.25" x 2.5"
• Inlet & Outlet: 2.5" / Tank Wall Thickness: 5mm / Max PSI: 22
• Robust, one-piece cast aluminum end tanks withstand high boost pressures
• Mishimoto Lifetime Warranty

So from the Fab nine specs, the only difference is the core height at .25" less and thickness at 3.25" vs 2.50." So, and looking for education on this front: how will performance differ and since I am building for 200whp? Does it/will it make a difference on the volume of the intercooler?

Braineack

iTrader: (62)

the vibrant core is much better.