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Old 11-06-2009, 02:58 AM   #1
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Default My crapp DIY junk build

Ok well, I know most people don't like reading threads about half built setups, so I waited until it was basically done to make my thread.

Before anyone comments on anything saying it looks like ***, I know. Most of the welds were done with flux core before I got gas and started using solid wire.

I also know that there's several things that still need cleaned up, such as head sheilding, putting the IAT sensor in the piping, and various other crap.

However, here's the basic rundown of my setup:

-Freshly rebuilt 1.6L with new piston rings and forged rods
-DIY head cleanup/small amount of porting
-Ilovetaco ebay cast iron t3 manifold
-T3/T4 chinacharger, will get specs later
-HKS RFL BOV (I know ricerish but oh well)
-Tial knockoff external WG with real tial spring in it (VTA for now)
-3" downpipe and exhaust with v-band connector and smallish magnaflow muffler
-CXracing i/c and piping kit
-Megasquirt MS I that I assembled myself
-550cc rx7 injectors
-AEM UEGO WB

I have a few things sitting waiting for me to get a weekend off to be able to install it also:

-DIY WI setup, based off of this site:
Do It Yourself Water Alcohol Methanol Injection | Before You Begin
-1.8 rear-end swap (I will be doing this before I drive the car too much)

One other thing, I know the front bumper is cracked and hideous, it will be getting changed with a stock one when the car gets repainted.

Also, I haven't been a member here for 4 years and had no turbo setups, this is my 4th setup on this car.

Pics of minor headwork (most of these are before final smoothing):
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Next was the MS, which you all know what it looks like, but oh well:
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Next was the exhaust and downpipe, in this picture the exhaust wasnt quite done:
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Next is the somewhat haggard DP (ignore the paint):

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First weld I did after I got the gas (sucky):
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Wastegate hole cut in manifold and everything welded on, then wastegate dump tube made (will route into downpipe eventually):
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Motor in finally:
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Pictures of everything "done" and a few other random pics (this is when it gets ugly haha):

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Ok I'm done finally, also, sorry about the crappy cell phone pics.

If you have any suggestion please let me know, but keep in mind I'm aware that I need heat sheilding and other odds and ends, they are on the top of my priority list.

Thanks
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Old 11-06-2009, 03:14 AM   #2
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GL! it's a learning process!
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Old 11-06-2009, 07:40 AM   #3
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Nice. I am wondering what if anything the heat from the dump tube is going to do to that plastic coupler on your intercooler piping...

How much do you think you spend on the water injection?
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Old 11-06-2009, 10:41 AM   #4
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Man...looking good.

You weren't kidding about being the DIY type. Hope to see it running soon.
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Old 11-06-2009, 01:18 PM   #5
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Quote:
Originally Posted by 94mx5red View Post
Nice. I am wondering what if anything the heat from the dump tube is going to do to that plastic coupler on your intercooler piping...

How much do you think you spend on the water injection?
Thanks, and that's one of the main things I'm concerned about, If im not happy with it after i try some head wrap or something on it then I'll just redo that pipe, took 5 minutes in the first place anyways.
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Old 11-06-2009, 01:20 PM   #6
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Quote:
Originally Posted by gospeed81 View Post
Man...looking good.

You weren't kidding about being the DIY type. Hope to see it running soon.
Thanks, and yeah, im ready to drive it for real, been waiting it seems like forever for this setup to be done. I've driven it about 10 miles total so far, so far so good.
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Old 11-07-2009, 02:54 AM   #7
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Good luck brother!
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Old 11-08-2009, 04:33 PM   #8
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Quote:
Originally Posted by 94mx5red View Post
How much do you think you spend on the water injection?
I'll end up having spent about $150 after i order the tank, thats for a basic non-progressive setup
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Old 11-12-2009, 02:38 PM   #9
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Took the car for a drive today and worked on tuning, got it much much better, to where it actually pulls all the way through the rpm's and doesnt bog down in boost from being too rich..

Anyways, for those curious, spool is slow to be expected, I am getting 8psi at about 4200 rpm, but I'm sure with more tuning, a boost controler, and eventually spark tuning that I can improve that a decent amount.

It felt very good though, pulled strong, and the external wastegate wasn't as loud as I was afraid it would be.
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Old 11-14-2009, 05:37 PM   #10
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Well I tried putting my 1.8 rear-end in today, and didn't have a big enough socket (29mm or 1 1/8" I believe)

Couldnt find one at lowes or home deopot by itself, and i'm not going to buy an entire socket set just to get the one socket.

Where did everyone find their big *** socket at? I might just have to order one online.
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Old 11-14-2009, 10:08 PM   #11
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Autoparts stores usually have those big *** sockets individually packaged.

Build looks awesome, get some videos once its tuned!
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Old 11-14-2009, 10:15 PM   #12
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Good stuff man! I love this kind of build. Maybe I missed it, what are the specs on that chinacharger?
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Old 11-14-2009, 10:48 PM   #13
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Awsome build dude! props!!
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Old 11-15-2009, 12:56 AM   #14
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Quote:
Originally Posted by Fireindc View Post
Autoparts stores usually have those big *** sockets individually packaged.

Build looks awesome, get some videos once its tuned!
Yeah I finally found one tonight, it was only $9 too, i expected to pay like $20 for some reason. Now I just gotta break these damn nuts loose.
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Old 11-15-2009, 01:00 AM   #15
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Quote:
Originally Posted by NA6C-Guy View Post
Good stuff man! I love this kind of build. Maybe I missed it, what are the specs on that chinacharger?
Sorry I forgot to post them, it's pretty big for my motor, I might eventually swap the turbine wheel and housing with something smaller, but I'm not sure.

Compressor Specs :
2.150 Inducer
2.207" or 56.06mm inducer
2.567" or 65.20mm Major
Compressor .50 A.R.
Compressor 57 Trim
M24 / T4 Compressor Housing
Turbine Specs :
T3 Type Turbine
2" Exducer
2.756" or 70.00mm Major
2.131" or 54.14mm Minor
.63 A.R Housing


BTW, i really appreciate the compliments and encouragements guys.
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Old 11-15-2009, 04:16 AM   #16
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Well started on the diff swap, go down to actually pulling the axles out of the wheel hubs and could not get those ******* out, I'm using a puller and still cant get it to budge.

It's to the point where i cant turn the bolt on the puller anymore with a ratchet and cheater bar, so I'm going to have to wait until I can get ahold of an impact gun to use on it. I knew it would be hard to get those axles out but **** they are in there!
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Old 11-15-2009, 10:53 PM   #17
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I'm thinking my best bet may just be to take the axles and hubs off together and taking them to a shop with a press and getting it pressed out. What do you guys think? This ****** will not come out.
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Old 11-15-2009, 11:43 PM   #18
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I went at mine with an impact hammer for about 30min until it slid out. But if you can get it to a shop it may be an easier solution.

- Harbor Freight Tools - Quality Tools at the Lowest Prices
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Old 11-16-2009, 12:20 AM   #19
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Quote:
Originally Posted by ssmith View Post
I went at mine with an impact hammer for about 30min until it slid out. But if you can get it to a shop it may be an easier solution.

- Harbor Freight Tools - Quality Tools at the Lowest Prices
I almost went and bought one of these today, however tonight, I went out in the garage to stare at the car in anger. Then I decided you know what, I dont care if i ever get to use these old axles again, so I proceeded to pick up a big hammer and wail on the axles, and sure enough, they came out after a few minutes. (I'm sure my neighbors loved that)

So, now the 1.8 diff swap can continue, and hopefully I'll have it done in the next week or so (I'm about to have to start working 12 hour shifts and weekends so work will go slowly)
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Old 11-16-2009, 01:08 PM   #20
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I would bought a turbo without the internal or built in WG as you have an external one.

Just FYI, the weld where the wastegate is attached to will give up at some point, trust me I have seen it happened. I would have welded a longer tube and attach brackets to it so it can hold under heat and vibration.

The WG does not need to be super close to the manifold.

I bet the car must be super rich at idle or low rpms, What is your WB readings?

What is the compression [email protected], [email protected]?

Another thing, you have to watch out when porting the cylinder head, especially on the intake side. The texture roughness usually found on the intake runners is control the speed of the fuel and not just spit it out the exhaust side. I have seen it happened before where people go crazy smoothing and widening the ports and at the end what they did was kill the CH.

It has been proven there is people here running 200 + hp on stock CH which deliver good air flow, besides turbo likes smaller runners, do not confuse volume with velocity.

Besides that good build, I like the pictures very much, the welds are great, I cannot even weld, have to get wallet raped anytime the car needs welding. I have a similar T3/T4, but mine does not have the WG, my car is 1.8 with high compression.

What I do not understand is you have MS so you are suppose to control the fuel at the bottom end if it is too rich.

How do the spark plugs look like after letting it idle for about 2 minutes?

WHat spark plugs are you using?
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