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DIY Turbo Discussion greddy on a 1.8? homebrew kit?

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Old 03-16-2009, 08:33 PM   #1
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Default After some research

Im ready to start putting my Turbo kit together.

Let me know if I'm on the right track here.

A friend of mine at work gave me his Td04 that has about 30k miles on it. It looks good, and he has had no problems with it he just upgraded his WRX and exchange for towing his car up to the tuner he gave me his turbo.

After reading several threads on here it looks like a TD04 will work but it looks like I'll have to fabricate some parts. I plan on building it in stages. I have already put on 16" rims, and bigger brakes. Additionally, I also installed a new heavy duty clutch. My end stage goal is to have a 220 RWHP on pump gas c but I will do that over a 2 year period. That way I can build, learn , build learn etc.

So,First off I was going to go for 5 lbs of boost w/o an intercooler
Here is what I was planning on for this:
1)Mega squirt from Corkey. I believe that system will take me a far as I want to go.
2) New fuel pump, figured this one is a little old and car would best be served by replacing
3) Exhaust manifold: this will be a bit tricky since I can't seem to find one that will match the TD04. One of my employees at work can weld and fabricate. I figured I could use a manifold that has a round outlet, cut off the flange, then weld on a new flange, drill and tap the new wholes to match. If anyone knows of a place that sells the exhaust manifolds that will fit a TD04 please let me know I could not find one.
4) Down pipe: looks like there a lot of WRX 3" down pipes out there so I figured I could get one of them, then, if I need to bend it and cut it to fit I would do that. ( pipefather I read your thread what did you use?)
5) Intake: w/ BOV, figured E bay special for this.
6) Odds and ends: boost gauge, air to fuel ratio gauge, intake temp. Gaskets, additional piping for exhaust.

Further down the road I'll go to 3" exhaust and intercooler.But thats another day.

I have spent several hours reading the DIY threads and various build threads. Any feedback would be greatly appreciated.
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Old 03-16-2009, 08:59 PM   #2
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Check here for your exhaust manifold. Probably your best bet for a manifold.

http://jgsturbo.com/index2.html
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Old 03-16-2009, 09:06 PM   #3
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Quote:
Originally Posted by wormfighter View Post
4) Down pipe: looks like there a lot of WRX 3" down pipes out there so I figured I could get one of them...
It'll only be useful for the flanges and the piping itself. It won't be anything remotely close to bolt-up. (just look at the differences in turbo location between the two cars!!)
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Old 03-16-2009, 09:08 PM   #4
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Looked there already. They have the exhaust flange I need but not the turbo flange. But it would be at a 90% solution and it appears that it would be a lot less costly. Any feed back from the supplier?

Last edited by wormfighter; 03-16-2009 at 09:18 PM. Reason: typo
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Old 03-16-2009, 09:17 PM   #5
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Originally Posted by kotomile View Post
It'll only be useful for the flanges and the piping itself. It won't be anything remotely close to bolt-up. (just look at the differences in turbo location between the two cars!!)
Figured there would A LOT of work there too. Thats where Im wondering what would be easier? WRX down pipe that has flange then bend piping to fit or, Miata down pipe but then bend and cut to fit turbo?
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Old 03-16-2009, 10:04 PM   #6
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Get your turbine flanges from Weirtech (he's a member here). Short of making a custom downpipe there's no real solution to the downpipe problem. I made mine using a weirtech flange and two 90 deg. mandrel bends.

For the manifold your best bet is to use the JGS, or if you're on a budget, use this:

eBay Motors: 89-93 MAZDA MIATA 1.6L B6 CAST T3/T4 TURBO MANIFOLD (item 330313414772 end time Mar-16-09 18:20:27 PDT)

And make a 3/8" adapter plate that has counterbored holes to mount to the t4 flange, and through-holes to mount to the WRX flange.
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Old 03-16-2009, 10:26 PM   #7
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Your flanges for both the inlet and outlet of that Subaru turbo can be purchased here if necessary:

Weirtech, Precision Machining & Fabrication
Excellent supplier.

But I like the idea of buying the aftermarket WRX downpipe and cutting to change the angles to work. They have a nice 3in diameter and a good wastegate merge bellmouth on most of them. I'd say that is a good thing to try, because I've already looked at it myself.

And with regards to MegaSquirts, have you read Braineak's sticky on the ones he builds custom? Might be in "For Sale" section.

Good luck.
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