New DIY turbo setup from Greece
 

Hello,
Today i began my building process..

Car '99 1.8
Turbocharger Garrett GT2560
Manifold by hks
305cc supra injectors
Ebay intercooler
Ebay 2.5" intercooler piping
Custom 2.35" exhaust
Ebay mbc
E-manage Blue
Zeitronix Wideband Controller
Olderguy's O2 Clamp
Custom mono-piston vta BOV


I installed some of the things today but unfortunetaly one of the 4 injectors is defective so i have to wait 2 weeks for proper tuning.
My engine is stock and i am planning to take the pressure up at 10 psi.
Any suggestions would be great!
Tomorrow i'm going to post some pics of the install.

Thanks for watching :)

Curious, why the 2.35" pipe, was it the cheapest you could get or readily available? I'm guessing so just wondering

tyte JDMz pipes have funny sizes as well (metric conversions?), maybe its just difference in abundances

can't wait, post some pictures of the install :)

I've got it for free from a friend of mine who used to run a similar setup. Do you think it's small?

BTW sorry for my english.

it may be a bit on the small side, I think 2.5" is a good start, but at least it will get you down the road. Don't worry your english is fine, better than some of the newer member's english

No, just a weird size. usually you only see 2" 2.25" 2.5" 3" etc...

Your english is fine, even better than some of the people that show up here who only speak english.

EDIT: Dang, beat to it by mazda/nissan this time.

Yes it is a weird size, but here in Greece the common sizes are 60 , 63.5 , 70mm

Thanks for the support about my usage of the language!

It may be a tad small, but it will do you fine for now, especially for free.

Maybe someday down the road you will benefit from upgrading, but i wouldnt worry about it for now, make sure to take lots of pictures.

Alright! The first thing i'm going to do tomorrow morning! (now here is 22:30!)

for up to 200hp he should be fine with that size, it's probably a 2.5in outer diameter anyway.

I've compared my dimension with an Evo's 7 oem exhaust and figured out that mine was bigger.(i'm talking about the exhaust..:))

Ok, here are some pics as i promised. These pics are 2 days old so and the car is actually ready in the engine bay right now.Unfortunetaly i ran out of battery from my mobile phone.
Please forgive the bad quality..

Intercooler was pretty easy to fit thanks to Mazda's ready made holes. Thanks Mazda!
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Here is the Oil return..
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And some general view of the enginebay..

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Fitting of the o2 clamp.. hope it stays dry there.

http://i2.photobucket.com/albums/y39...C081030014.jpg

More pics of the finished engine bay on Monday. Thank you for viewing!

Looks great man, keep it up!

+1. Free parts always work better. :) Nice looking build. More pics would be cool. I'm guessing that's JB Weld or something similar on the drain? I see many people do that. I might do the same.

I'm afraid I dont know what JB weld is.
It is some kind of high thermal resistance glue. Dont know much about it, except of the fact that works fine!

JB-Weld is a mechanic's best friend :giggle: EDIT: Except for a BFH.

J-B Weld - Wikipedia, the free encyclopedia

Yeap!! That's it! I hope it lasts...

Farmers used to use it here, to splice together broken equipment. It would hold for a good bit. I would break again, but atleast they could get through the day or week till they could get it welded together properly.

It should never go bad for what you are using it for. And that is what FM advises you to use.

That's are some great news Toddcod!

Lol, we could make a thread on things fixed with JB Weld... Seriously. It's really great stuff. Saw a car where they cracked the oil pan on the automatic transmission. Cleaned it, siliconed it to stop the leak, and JB Welded it. 3 years later they sold it. Still see the car running around once in a while.

Yeah I'll probably do this to my pan I guess. I don't want leaks, that's for sure.

Clutch pedal snapped in half on my old 240sx...lil bit of jb weld and she was good as new...still going strong for the new owner 2.5 years later :giggle:

Alright. The car fired up right away with the best idle i could get!

I m very happy with the result except of the fact that the turbo starts spooling at 3.000 rpm. I hope this is a wastegate fine tuning problem, because it is a monster!
We tuned it for minimum boost but she made 10-13 psi at full boost. I would be happy if i could maximize my boost to 8 psi because i m running right now stock 240cc injectors. In first and 2nd gear the the duty cycle reaches 100% .And this is bad..
Beside these, the car feels great. I ve never had a turbocharged vehicle in my life so I m very happy with it and cant stop burning fuel!

Here are the final pictures. Unfortunetely I didn't have time to install the bov so i have some idling problems when i let of the throttle. It runs way to rich to 9:1 and then some times dies.

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Hello!
My idling problem disapeared completely.
The solution was found when i put an extended pipe between the maf and the inlet of the turbo. So maf needs to be away from the turbo for sure...
Everything seems to run fine.I will post some videos soon.

Thanks for watching!

Some updates.

gt2560r has been replaced with a gt2871r, 3" full exhaust and 8 injector setup. and the engine is now fully forged with wiseco pistons ,eagle rods and arp goodies.

Some photos
8 injectors setup
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GT2871R
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The engine bay (dirty as hell but that is just me)
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Other

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nice build man. Don't you think you should just get good engine management instead of running that monstrous setup of 8 injectors and a primitive unit like emb?

If it has been mentioned/discussed I apologize: didn't read whole thread.

You are definetely right man, emb sucks but it gets the job done with pretty solid afrs and it's fairly easy to be tuned from a newbie like me. Before the extra injectors installation I hated this unit so much but now I m quiet happy with it.

Killer hardware upgrade...now it's time to bring management up to par and make the most of that big turbo and 3' exhaust.

Awsome. Thats how it starts, 8 or 10 psi then forged guts and a big churbo.

Fixed. His is a real Garrett.

If it works well, that's good. The hydraulic hose shop must love you.

Good job.

:laugh::laugh::laugh:

I am officially done! Didn't have time for a dyno but the car is pretty fast.

Final Specs

Garrett GT2871R @26 psi
HKS manifold
Tial 38mm external WG
AEM water/methanol injection
Rx7 tii tranny with adapter plate
MS2 extra
800cc denso injectors
Toyota cops
Bosch BOV
3" custom exhaust
Greddy profec spec II
Zeitronix Wideband controller
EMUSA intercooler 31x12x3
Ebay alloy radiator

http://sphotos.ak.fbcdn.net/hphotos-..._6147998_n.jpg

Fitting a big intercooler? No problem!

http://i2.photobucket.com/albums/y39...g?t=1276181581

Congrats man, it looks good! Only took 2 years :P

Stock differential?

Yes the stock torsen. With a "mechanical empathy" treatment.

I bet it's a beast, any dyno numbers yet??

Now that is an intercooler!

Pretty awesome setup. How's the turbo longevity situation coming along?

So far so good.(knock on wood)
No dyno yet but you'll get one soon!