Boost addicts 90 na, 2002 vvti engine, t04e twin scroll turbo, fully custom build
 

Hey everyone, it's been a few years since I've logged in here. I was out of the country for a bit setting up and managing a company in Kuwait called Bullet performance, all High performance exhaust systems and turbo systems. Recently I got back to south Florida, working on a few things, and getting my own high performance exhaust and turbo system company set up!

You could say I'm a master fabricator and welder, so you all will enjoy seeing me put together my car.

Heres a few pictures of some recent work of mine for those of you who like seeing high quality custom fab parts.
My Instagram is @zanderguerra if you want to https://cimg2.ibsrv.net/gimg/www.mia...814588c36.jpeg

https://cimg2.ibsrv.net/gimg/www.mia...0a36b4ca9.jpeg


Ok ok enough of all of that.

So so I got my old Miata out which had (literally) shot some engine parts into i95 about a year ago. It was really dramatic and hilarious, a huge explosion of fire, Rods tumbling on the highway, just epic.

So ive got this 2002 engine, 60k on the block and a refurbished vvti head, so let's call her half new. I'm going to run her at 10psi on this lower end, but I'll throw a built block in later and turn the boost all the way up. Expecting 250whp or so at 10psi, but with a built motor I'm guessing 450whp? We'll find out.

So so the turbo manifold is the first thing I'll start making. Building her a totally equal length turbo manifold in schedule 10 stainless pipe. 1.25" to start but it will actually go up to 1.5" before merging, a true stepped runner design. Again this will be a twin scroll manifold. Now even though I don't have ac and power steering on my car currently, I want this manifold to be able to fit with both ac and power steering, as I plan on producing this manifold In production, so.. It's gunna be a tight fit! Kind of a side mount setup design.

Here's a little work I started on. Didn't like how my exhaust housing didn't have a way to center my Vband, so I lathed a little grove for the tube to center on. Also took the time to machine off the stupid lip on the Vband itself that allowed it to work for 3" or 3.5"... Let's be real 3" flows way enough.
https://cimg0.ibsrv.net/gimg/www.mia...cb2a07cbb.jpeg

https://cimg1.ibsrv.net/gimg/www.mia...67c368575.jpeg

https://cimg2.ibsrv.net/gimg/www.mia...9e9e362a4.jpeg


Heres a page of some sketches I've done on the turbo manifold
https://cimg4.ibsrv.net/gimg/www.mia...7913906ba.jpeg


Heres a box of stuff I ordered. More stuff on the way.
https://cimg5.ibsrv.net/gimg/www.mia...8cca43b0c.jpeg

Stay tuned! Gunna pull the old motor tomorrow and start dropping in the new motor Saturday. Figure I'll finish her up within a week or so after that.
Side note too. I'm at a maximum $2000 into this to make her work completely. That's including the motor with its included ms1 I'm getting from my friend. This includes things like a nice new tial 44mm wastegate, all beautiful and new Mandrel bends and such. So goes to show, things aren't too expensive when you build them.

Very cool to see you come back to mt.net!
A bit of praise: Your fabrication thread inspired me to design and fabricate my own turbo setup.

ah thank you! Finally after attempting 1000 different combos I figured out my old password.

Fabrication thread?! I remember it now!! Hahaha totally forgot, I'm going to go check her out if I can figure out where it is on here.

I'd love to have a manifold fabbed

we can work out something.

you running a log mani now? Excuse my lack of desire to dig through your build to find out.

I'll shift to PM

Wow, fantastic looking fab work. Pretty stunning pieces you have. I went ahead and followed because I love seeing fab stuff on my feed.

Following this closely. Also planning a twinscroll manifold.

But with a 2002 motor (VVT) you should step up to an MS3.

thank you!


yeah man I'm a big twin scroll fan! Helps out a lot on a street car.

Yeah I mean motor is 600$ with the Ecu, package deal from a buddy.. Soooo yeah for now vvti is disconnected. I'll probably upgrade her to an ms3 when I build the motor, I want to be able to control her properly at a high power level. This first run is me kind of just fucking around really.

Good. Not a bad plan.

What are you doing for a wastegate solution. I've seen a couple different options.

Twins? Or some sort of divider.

yeah twin gates are pricey, I'm running a divided setup into a single 44mm tial. Plenty of wastegate really. She'll sit right above the power steering pump, tucked between the motor and turbo.

Cool. That was my idea too. No PS/AC so I'm going to try low mount with the wastegate above the mani. Dumping down next to the downpipe.

I wanna talk twin scroll with you guys :3

Manifold is a pain in the ass to build. But you get a decent spool gain, and a small power bump. Compared to the same sized single scroll turbo.

You know. I need a twin scroll manifold built....you need an MS3x built....maybe we can work something out :)

That's possible, let's see how the numbers crunch. Pm me


Alright so I've made some moves today! Got the car over here in my shop, ready to tear out the old and destroyed 1.6 and drop in the 1.8. Should have that new motor in by tomorrow.

Some more gifts arrived today in the mail!

Again this whole turbo manifold has some key points to it that make it unique

Equal length
Twin scroll
Schedule 10
Stepped runner design
Fits with ac and power steering

Can anyone tell me if anyone else has made a manifold that fits with ac and power steering as well as being equal length, and even twin scroll? Forget about it being stepped runners, nobody has done that on a bp turbo to my knowledge.

I am loving these little transition pieces that go from 1.25 to 1.5 pipe, they are gunna flow like biggie smalls.

https://cimg7.ibsrv.net/gimg/www.mia...19be7b57c.jpeg


That's all for today. Probably Sunday I'll start on the turbo manifold mock up.

@TurboTim designed one. Don't know if it ever got made.

https://cimg1.ibsrv.net/gimg/www.mia...dabce929f.jpeg

You guys will like this too. A picture through the hole that appeared in the oil pan.

should have read more miataturbo.net before you boosted.

why? I've built more turbo kits than I can count

"Can anyone tell me if anyone else has made a manifold that fits with ac and power steering as well as being equal length, and even twin scroll? Forget about it being stepped runners, nobody has done that on a bp turbo to my knowledge".

Hi Boost, for what it's worth I'm built mine about a year ago. I didn't start from a clean sheet of paper, but I've super happy with the results. AC is intact but I'm running a depowered rack.
https://www.miataturbo.net/diy-turbo...o-build-79259/
What compressor housing are you using?

I think he was referring to you thinking that schedule 10, equal length and ac fittment was something new. ARTech,Turbo Tim , and even Shuiend have been at this a while.

I think he's referring to tuning and not blowing sh*t up.

Looks good! I like those Evo turbine inducers.

Yeah I mean I did a bit of searching, but I think it being such a specific request made it tough to find. Very rare to find ac, power steering, equal length, twin scroll and sch 10. Yeah I personally won't be running power steering, but I need to put ac back in my car, Florida is just too hot. I do want to be able to sell these though, so for what it's worth to me it needs to be able to fit with all of the cars accessories. Turbo is a 50 trim t04e .63 twin scroll rear. Genuine Garrett with zero miles, just been sitting on a guys shelf, $350 was a steal lol

Good to see its been done though. Nobody has done a stepped sch 10 turbo mani on one of these though I'm pretty sure, so I'll have that lol.

To the above, yeah it's gunna be fine man, I've seen 1.6s make 1200hp. I didn't say Miata, but whatever it's just another engine. I'm producing my first win turbo Gallardo systems soon, I'll feel more worried about guys who want 2000 hp there than this little guy at 500. I'll probably pump like 400ccs of water pre turbo when I build her too, a bit of head work and cams. Can't see why 500whp+ isn't possible with this turbo. Just needs a nice intake mani, I'll whip something fun up.

So ive done a little bit of work. Got my old motor out, received my new motor. Still gotta do little things like drill and tap the oil pan. Still gotta clean up some more parts, do some more sandblasting. Hopefully can get the motor in tonight and begin mocking up my manifold tomorrow!

https://cimg9.ibsrv.net/gimg/www.mia...84524a7b5.jpegMy fresh 1.8

https://cimg0.ibsrv.net/gimg/www.mia...03ae5aae1.jpegTrimmed the front cover off to my likings, then sandblasted her. Still not sure if I want to paint it or not, sandblasted surfaces don't stay nice easily..

https://cimg2.ibsrv.net/gimg/www.mia...3954b90c8.jpegVertical flow core I found laying around. Not my favorite look and packaging, but they're efficient.

https://cimg4.ibsrv.net/gimg/www.mia...4c4cdbd72.jpegNot quite done here, but I gutted and ported this intake. Kind of a waste since I'll be building a custom intake for her soon enough, but it should be worth some ponies with more laminar flow and a larger plenum!

I didn't do a twin scroll equal length that fit with A/C & P/S, but I'm sure it's possible.

Also, people describe their manifolds as 'equal length' if it only kinda sorta looks equal.

powder coat clear?


On that note, will the VVT solenoid housing gasket seal up against a media blasted surface? Don't know if the surface has to be refinished or if it matters since the gasket material isn't rubber. Also hopefully your vent passages are all clean of blast media. That shit is nasty for motors

That is a bit of a harsh way to put it, but there were significant spool gains and midrange torque gains to be had with VVT. You've lost that, but at least you still have the higher flowing NB2 head.

Here I've got a few for you now, there will be more.



https://cimg9.ibsrv.net/gimg/www.mia...3f529caec.jpegI like little details like this little plug I machined. Only took 3 minutes, but looks clean.

https://cimg1.ibsrv.net/gimg/www.mia...37e7fbab1.jpegWelded from the inside!

https://cimg0.ibsrv.net/gimg/www.mia...3e72e028f.jpegThe block off plate that I made for my TEMPORARY inactive vvti. Surely I'll hear another story about how this is stupid though, even though my ms1 can't control it lol.

https://cimg2.ibsrv.net/gimg/www.mia...80ae5580c.jpegSomething like that, still dialing in the exact position.

https://cimg4.ibsrv.net/gimg/www.mia...f00269ece.jpegAlways use engine hoists to hold your turbo in place and your gunna not be so mad at everything. Making sure I've got an inch all around that turbo so I can build a kit with any turbo any customer requests.

https://cimg5.ibsrv.net/gimg/www.mia...2c668a294.jpeg

https://cimg8.ibsrv.net/gimg/www.mia...164468e65.jpeg

from

Subscribed for fabrication pics and information... staying sub'd and following on Instagram. No issues here. Really looking forward to seeing what you put together. Even though I wouldn't agree with the VVT move, I have to say the parts you machined to do it look damn pretty.

I am pretty sure you are going to have oiling issues with that block off plate on the VVT section. I believe the cam gear will need to be filled with oil even if VVT is not enabled. I would not run the car like that and expect the head to last.

Still to be determined, In my opinion. Its still super early in the build stages, but I haven't seen anything earth shattering yet. The plug is a good first project for an intro to lathe workmanship. Not trying to shit on this thread, but a little less patting ourselves on the back, and more sweet parts would be cool. The "I'm a bad ass, look at me go" attitude is kinda cheaseball. Call me a master fabricator, this took me three minutes, etc.

Still really interested to see this build materialize. Keep going, we want to see cool stuff!

I was just going to post this, I think the first bearing in the cam gets its lubrication from the VVT gear.

Pretty sure without oil pressure, the vvt assembly will eat itself alive.

EDIT: I'M always late around here..

I just don't like seeing vvt heads goto waste.

You can use the ms1. You just need to hook all the oil lines up to the cam gear. Then just leave it unplugged. You will need the cam sensor one day when you do want to make vvt work.

Might be worthwhile just finding a BP4W head for simplicity. Then you can build the VVT head while you have a functioning motor and go ape nuts with t4 twinscroll

Anyways, despite all of the distractions from my car I have gotten a start on my turbo manifold. this part took a bit of time to think up, the manifold is kind of built around it, it has to be built first.

This is is a true 4 into 2 design, with a split passage wastegate tube going to a single gate.


https://cimg6.ibsrv.net/gimg/www.mia...31ed6c0cc.jpeg

Sure. Just as long as you stop being such an entitled prick that gets offended at the slightest criticism.

Cleaning up your thread now.

Just FYI, the #1 camshaft journal is oiled from the VVT mechanism that you've removed. The others are oiled from the cylinder head, but that one gets lubrication from the VVT system. Your cylinder head will last around 5 minutes in its current configuration before the intake cam seizes/breaks from oil starvation.

thank you, yes someone has pointed this out to me already. Does anyone have a diagram for the oiling on this vvti head? It appears the oil goes up into the solenoid and then back down. I could always throw a plug in there and that would complete the cycle.. Assuming I am seeing it correctly. Yes I know all of you think it's pointless to block it off, but again my ms1 can't control it, and quite frankly I'm not in the mood to go buy all these vvti parts which I don't have, just so it can sit there doing nothing. Anyone that can confirm or deny what I just said above would be much appreciated.

A few pictures I just snapped of my slow progress. Been getting distracted by a water cooled exhaust for a supercharged 13b speedboat.


https://cimg3.ibsrv.net/gimg/www.mia...cb3bc975b.jpegCut, beveled, wire wheeled and cleaned.

https://cimg5.ibsrv.net/gimg/www.mia...eefaffccf.jpegTacked

https://cimg6.ibsrv.net/gimg/www.mia...69ac57f52.jpegMaybe I can have her all tacked and done by 2am, gotta stay focused.

Did your VC not come with the part that goes above where you blocked off? Honestly you might as well just purchase that now, as you will need it eventually. You keep saying you want to block it because your MS1 can't control VVT. You just leave the damn thing unplugged and will work exactly how you want it blocked off, but then when you can control it you just plug in the plug.

Just to answer your question, no you can no just add a plug and feed oil to it.

No "plug" added anywhere in the system will cause oil to be provided to the #1 cam journal. You need to reinstall the spool valve, solenoid, and VVT oil system if you expect that cylinder head to survive its first trip around the block.

I think he means drilling a passage of some sort in the plug. I'm not sure.

OP, I'm going to bust your balls for a second here.
Those welds don't look like your instagram pics. They look like my welds when I forget to drink water, but choose tons of coffee instead. I'll be able to tell if you go back and run them over with a smoothing pedal, so watch that shit.

Hahaha.

No combination of the words "drill", "plug", or "welding" will result in oil magically traveling through his block-off plate into the #1 cam journal.

I dunno, maybe it's the kick-off campaign for his sister business: Shrapnel Tuning -- a subsidiary of Bullet Fabrication.

editied

0
no.
well, you're clearly on your way to scrapped motor #2.
so what? I've had sex with at least 15 men.
I really haven't. Cool you can weld. How does that change the fact you're making horrible choices about your miata?

Edited

Waits...

No I cant. Went back and actually read words.

Doesn't change too much.

If you want info on the vvt actuator, read this post started by jasonc sbb: https://www.miataturbo.net/ecus-tuni...advance-27030/

I wasn't going to do this publicly.

When you publicly insult a positive member, who has been around for years, helping people, and producing good products, that's unacceptable.

It doesn't matter now that you have wasted your chance on this forum, but for future reference, don't insult your future potential customers. I, for example, might have a miata, but I spend 10's of thousands on it, just beacause it makes me happy (at least thats the idea) I dislike that you insulted a fellow forum member, therefore, it makes me not want to give you money for a service.

If you truly want to build a business that survives and thrives long term, you need to listen to your current and potential customers. I was very turned off by our phone converstion. You literally talked over me when i was asking questions. I had to ask the same question 4 times for you to answer it. Dont bother looking into my project, I do not want any part of your work.

Seriously? I took my time to sit and talk to you and answer all of your questions, giving you all of your different options.. you say I spoke over you? That doesn't sound intentional.. I am in a shop environment, it's loud in here, maybe I couldn't hear you taking? You seemed plenty happy with me on the phone, seems like this is stemmed from you reading this conversation. Honesty I'm surprised you're standing on the same side as the guy totally trolling my thread, but whatever. Regardless I have been insulted repeatedly by multiple members of this forum, and I'm done and tired. I'm just going to not post anymore, I don't need this. I came on here not to make customers, I came on here to share this build to those who care about fabrication, not to be a place for people to talk trash about my abilities and tell me my quality is low.. I don't have time for this bs, since nobody seems to care I this will be the last post I put up.

We want to see rad stuff. That's it. Post that sort of thing, and less rebuttals to argument. Post the parts. Like I said before, and I really didn't mean to be insulting. You came in here like a peacock all puffy chested, and didn't deliver. Granted you only had a couple days, but still. It's a good reason to lay low, play it cool and deliver the good stuff.

Dude, I seriously didn't mean to be offensive. What you showed this far, was not what you were touting.

Hopefully you stick around and throw up pics of progress.

Just post build stuff and ignore the rest. Do it for me. Do it for the lion in the cardigan.

Yup

Well I just had someone call me who told me that he was hoping to watch through this little build, and that I shouldn't stop posting because someone in here is bothering me.. I suppose I came here to share some photos and that's all I'm going to do, ignoring them is a good idea I suppose. I'm not used to dealing with people doing that to me in real life, people genuinely don't act like that in the real world. I am a very modest and nice person, I don't have any enemies.. I don't understand why I get attacked. Why because I said I'm a master fabricator? Lol that word choice must have made someone upset, but fuck you know what? I feel like I can say that without being a prick, because I'm pretty damn good at this stuff.. I can't say that? People never doubt me until I'm on this MIATA forum, it's so crazy lol.

To ryansmoneypit you weren't so bad, there were a few that were unnecessary, a lot of old posts are deleted from here anyways now. I think you need a little patience on what you're wanting to see Ryan lol, it's not done till its done. I don't pulse over my welds when I'm done. I stated already I didn't use a large gas lense, i wasn't trying to keep it pretty and nice. That was a quick pass that will get ground down while ported, and the bit on the outside is going to be welded over with a root, no filler, then a pass with filler. I only do that on the flange, on the runners I only do one pass. Still get full penetration even on single passes. Final welds are with a big cup flooding at 40cfh.

Back to the thread.. Here's some photos I just snapped of where I am right now. Still too many distractions around here with other little jobs. I put aside a week to get this car together from other work, but it tends to make its way in.

only one runner done for now, one on the car and the rest on the bench. Don't mind the non polished runner, it will be shined before welding. I individually tac weld each runner till it's all done, then I break all the tacks on the flange, and on the collectors. At that point I individually wire wheel shine all of the tubes, clean them, and weld them individually, before putting them back on for a final weld.
https://cimg7.ibsrv.net/gimg/www.mia...26398e9ba.jpeg

https://cimg8.ibsrv.net/gimg/www.mia...f389feb72.jpeg

Looking real good. Please continue with the photo goodness.

https://cimg8.ibsrv.net/gimg/www.mia...78fa8b542.jpeg

https://cimg4.ibsrv.net/gimg/www.mia...8f780ddec.jpeg

https://cimg5.ibsrv.net/gimg/www.mia...77f7395b3.jpeg

https://cimg7.ibsrv.net/gimg/www.mia...45d7f1684.jpeg

https://cimg6.ibsrv.net/gimg/www.mia...d0cd2fd36.jpeg

Feeling pretty toasted right now, but I feel good. Not far now! Still gotta make my wastegate entry, break down the manifold, polish, weld, re-assemble, and final flange and collector welds. Still some days ahead of me before she runs.

I want to say I have gotten this manifold so incredibly equal between the runners I'm surprised it actually worked so well. I'd be seriously surprised if there is more than a 1/4" difference in length between them.

Very nice work. Great quality photos as well.

That was fast. Really fast. Awesome tube fitting as well.