Scott's Turbo build!! (Finally!)
08-02-2009, 04:03 AM
#1
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Location: Overland Park, Kansas
Posts: 5,360
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Scott's Turbo build!! (Finally!)
Today I broke ground on what sadly will be a long process to complete. There is a lot of work that needs to be performed in order to complete the install.
Figured it was time to start my build thread which I've been looking forward to since I signed up 2000+ posts ago.
Heres what I've got!
Homebrew weld-el log manifold
Garrett T3 .63 Turbine housing
Turbonetics T04B S-3 CompressorTurbonetics Deltagate w/7psi spring
CXRacing 28x7x2.5 IC & Pipe kit
Enthuza TurboRacer 3" SS catback
Enthuza Test pipe
MSnSE v2.2 029q4, EBC, Fan, Tach, launch control, Shift mods
(Sad I can't use water injection output AND Fan output both..)
LC1
Toyota COPs
Stock intake manifold
Stock 265 Injectors
Rebuilt Cylinder head < 10k miles
190k+ Smokin' Shortblock
SPEC Stage III Clutch
Stock torsen
Today I started the build off with fabricating a bracket to bolt the intercooler in. Picked up the CXRacing 28x7 IC without even checking to see if it'd clear the A/C Drier, which it didn't. Fix to that was unbolt the drier and push it up and over to the passenger side much as possible, then make another little bracket to bolt it back down. That gave plenty of clearance for the IC to fit in the opening. It ended up hanging a little bit lower than I wanted, but its acceptable for sure. The bottom of the IC is about the bottom of the radiator now. Will post pictures of the IC bracket when I powdercoat it sometime this week. Pretty solid constructed from 1/2" angle stock and bolts to the horn location's bolts. Planning on making some bottom bracing also from the same angle.
Tasks left to complete:
Weld T3 flange on manifold
Weld wastegate flange on bottom
Get hardware
Mount turbo
Build downpipe
Build wastegate's pipe
Build Cold side pipes (should be easy if I can find a different radiator)
Build hot side pipes
Grind out A/C bracket to clearance for AN Fitting return line
Weld on BOV flange
Weld on IAC & IAT bungs
Still tons of work to be done and its going to take some time sadly. Will make sure from now on I take tons of pictures. Was so engrossed in what I was doing just completely slipped my mind to take more.
I want to get a large aluminum radiator but I'd like the water inlet on the top tank located elsewhere. Would be absolute **** if I could put a 90 degree coupler right off the throttle body and shoot straight down for a couple more turns then into the intercooler. Not finding anything like that though.
So thats the slow and minimal progress of my build. Personally very excited, been waiting sine 2005 to turbo this POS.
Old Compressor on left, T4 compressor on right:
Had a T2 flange on it then decided to use my T3
Every build thread needs some cat... Hackercat will hax your interwebz!!
Figured it was time to start my build thread which I've been looking forward to since I signed up 2000+ posts ago.
Heres what I've got!
Homebrew weld-el log manifold
Garrett T3 .63 Turbine housing
Turbonetics T04B S-3 CompressorTurbonetics Deltagate w/7psi spring
CXRacing 28x7x2.5 IC & Pipe kit
Enthuza TurboRacer 3" SS catback
Enthuza Test pipe
MSnSE v2.2 029q4, EBC, Fan, Tach, launch control, Shift mods
(Sad I can't use water injection output AND Fan output both..)
LC1
Toyota COPs
Stock intake manifold
Stock 265 Injectors
Rebuilt Cylinder head < 10k miles
190k+ Smokin' Shortblock
SPEC Stage III Clutch
Stock torsen
Today I started the build off with fabricating a bracket to bolt the intercooler in. Picked up the CXRacing 28x7 IC without even checking to see if it'd clear the A/C Drier, which it didn't. Fix to that was unbolt the drier and push it up and over to the passenger side much as possible, then make another little bracket to bolt it back down. That gave plenty of clearance for the IC to fit in the opening. It ended up hanging a little bit lower than I wanted, but its acceptable for sure. The bottom of the IC is about the bottom of the radiator now. Will post pictures of the IC bracket when I powdercoat it sometime this week. Pretty solid constructed from 1/2" angle stock and bolts to the horn location's bolts. Planning on making some bottom bracing also from the same angle.
Tasks left to complete:
Weld T3 flange on manifold
Weld wastegate flange on bottom
Get hardware
Mount turbo
Build downpipe
Build wastegate's pipe
Build Cold side pipes (should be easy if I can find a different radiator)
Build hot side pipes
Grind out A/C bracket to clearance for AN Fitting return line
Weld on BOV flange
Weld on IAC & IAT bungs
Still tons of work to be done and its going to take some time sadly. Will make sure from now on I take tons of pictures. Was so engrossed in what I was doing just completely slipped my mind to take more.
I want to get a large aluminum radiator but I'd like the water inlet on the top tank located elsewhere. Would be absolute **** if I could put a 90 degree coupler right off the throttle body and shoot straight down for a couple more turns then into the intercooler. Not finding anything like that though.
So thats the slow and minimal progress of my build. Personally very excited, been waiting sine 2005 to turbo this POS.
Old Compressor on left, T4 compressor on right:
Had a T2 flange on it then decided to use my T3
Every build thread needs some cat... Hackercat will hax your interwebz!!
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.. looks like a great build cant wait to see the results
08-02-2009, 08:33 PM
#11
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Thanks everyone! I'm pretty stoked.
Didn't mention, I bought a box load of mandrel bends both 3" and 1.5" to fabricate the DP and wastegate plumbing. Should play out pretty well with a few bends and some butt welds. Still need a LOT of brushing up on my welding, but we'll get it. Also just remembered I need to get myself a cylinder of Argon so I can weld up the IC piping in order to avoid 10 silicon coupler failure points. Also requires me to learn wire welding aluminum. Joy!
Wastegate is something I've had sitting in a box for years. Don't think I even paid anything for it so we'll see how it works. If the deltagate gives me issues I'll just replace it down the road with the F38 Tial as they seem to share flanges.
I'd love to v-band everything but for now it'll just be the downpipe. Did just check out ATP's site and saw they've got a Tial turbine housing that I *THINK* would fit my turbo but I'm not 100% sure. Its ~300 and would be worth it when I build the new manifold. Will look into that for sure. The pile of parts on that bag were pretty expensive though.. Thats almost 200 bux shipped from ATP! Should make removing the turbo pretty handy.
I'm going to start out with the wastegate spring pressure then go through pulling what hair I've left learning MS's EBC. With this tired old motor probably won't go much past 12psi. If I could get ~240rwhp I'd be shitting kittens, but would be happy with 200. Waiting for a few dollars here and there is another block waiting for some forged pistons. Already have a good crank and H-Beam China rods. Would like to run down a 99 head and intake for that motor if I can get around to finishing it. With the forged motor I'd like to max out the turbo, which IIRC is around 25psi.
Actually I might just end up getting a full blown GT30 BB turbo eventually depending on how well this works. My exhaust housing is kind of large so we'll see. Pulled it all apart and checked the bearings which are in good shape, but since its been rebuilt before the CHRA is on its last leg, so to speak. Guy at the diesel shop said the bearings are already oversized for the housing and wouldn't hold another rebuild. Replaced the piston ring on it and he was nice enough to bead blast the turbine wheel. Oooh.. lol.
Scott; Give me a day or so to think about that compressor housing. Honestly doubt I'll ever end up using it.
Didn't mention, I bought a box load of mandrel bends both 3" and 1.5" to fabricate the DP and wastegate plumbing. Should play out pretty well with a few bends and some butt welds. Still need a LOT of brushing up on my welding, but we'll get it. Also just remembered I need to get myself a cylinder of Argon so I can weld up the IC piping in order to avoid 10 silicon coupler failure points. Also requires me to learn wire welding aluminum. Joy!
Wastegate is something I've had sitting in a box for years. Don't think I even paid anything for it so we'll see how it works. If the deltagate gives me issues I'll just replace it down the road with the F38 Tial as they seem to share flanges.
I'd love to v-band everything but for now it'll just be the downpipe. Did just check out ATP's site and saw they've got a Tial turbine housing that I *THINK* would fit my turbo but I'm not 100% sure. Its ~300 and would be worth it when I build the new manifold. Will look into that for sure. The pile of parts on that bag were pretty expensive though.. Thats almost 200 bux shipped from ATP! Should make removing the turbo pretty handy.
I'm going to start out with the wastegate spring pressure then go through pulling what hair I've left learning MS's EBC. With this tired old motor probably won't go much past 12psi. If I could get ~240rwhp I'd be shitting kittens, but would be happy with 200. Waiting for a few dollars here and there is another block waiting for some forged pistons. Already have a good crank and H-Beam China rods. Would like to run down a 99 head and intake for that motor if I can get around to finishing it. With the forged motor I'd like to max out the turbo, which IIRC is around 25psi.
Actually I might just end up getting a full blown GT30 BB turbo eventually depending on how well this works. My exhaust housing is kind of large so we'll see. Pulled it all apart and checked the bearings which are in good shape, but since its been rebuilt before the CHRA is on its last leg, so to speak. Guy at the diesel shop said the bearings are already oversized for the housing and wouldn't hold another rebuild. Replaced the piston ring on it and he was nice enough to bead blast the turbine wheel. Oooh.. lol.
Scott; Give me a day or so to think about that compressor housing. Honestly doubt I'll ever end up using it.
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07-08-2013, 05:12 PM
#19
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Ahem.
Please allow me to step into the excuse zone for a minute..
I am a terrible welder, horrible fabricator, a master procrastinator, king of the unfinished projects, a jack of all trades and a master of none, and have my hands fairly full between working a full time job and attempting to rehab a house I bought last August. Bought my first and only Miata in 2005 for $3000.00 and have mostly enjoyed owning it with a dream one day of installing a turbo yet my quest has been full of fail. I've failed, my car has failed, and the world has failed. Three engines, one supercharger, and a lot of blood sweat and tears later, I can finally say "Success!" Well, Sort of..
On a random craigslist search for a GoPro Hero3 video camera I came across someone on craigslist selling what appeared to be an SSAutoChrome manifold and downpipe for $50.00 with the claim it was cracked in a crash. After exchanging some emails I met this homeless looking "drifter" dude (who had THE shittiest looking Laguna Blue miata I've EVER seen) and exchanged my hard earned freshly printed ten dollar bills for one cracked SSAutoCrap manifold and effed up downpipe. Quick phone call to my brother (professional welder by trade) and the manifold was drilled and welded back up however my turbo was incompatible because of the turbine outlet flange.. Mine is 4 bolt, the downpipe is for a 5 bolt. Long story short, ordered a chinacharger from ebay, cut the flange off and the downpipe in half, bolted everything together and tacked the flange and pipe back together in preparation for final weld. Naturally the wastegate tube on the downpipe didn't even come close to lining up with my Tial, so instead of doing what I should have and ordered an internally gated turbo, I cut the wastegate tube off the downpipe and assisted with fabrication of a new one.
Here it is, in all of it'sglory failure:
I had off Wednesday and Thursday (3rd/4th July) and put in 9 hours total between the two days working on installing all of my parts. Finally got to start it Saturday evening, verified the turbo had oil flowing, no coolant leaks, closed the hood up and went for a test-n-tune. Running Paul's Timing map (which might not be a good idea...) and started with the VE table from a similar turbo'd miata for a base.
Car: 1995 C-Package
Motor: Stock 1996, head studs and new gasket
Head: Stock 1995
Cooling system: Stock radiator, bad DIY reroute (Godspeed aluminum radiator on order)
Manifold: SSAutoCrack nothitblock model
Turbo: T3/T04E, .50 A/R Cold Side, Ind: 1.99" (57.75mm), Exd: 3" (73.55mm), Trim: 48.9, Turbine Wheel .63 A/R Hot Side, Ind: 2.56" (52.76mm), Exd: 2.2" (75.46mm)
Wastegate: Tial 38mm, 10psi spring
Intercooler: CXRacing 28x7x2.5 (Have a giant Vibrant to install eventually)
Plumbing: Flyin'Miata Silicone IC pipes
BOV: Ebay special that doens't work
Exhaust: "Custom" (lol) open downpipe, have 3" stainless Enthuza to install eventually
ECU: Megasquirt v2.2, HR10
O2: AEM UEGO
Ignition: Toyota COPs
Injectors: RC550s (ID coming in the future)
Fuel pump: Walbro 255lph
Fuel Rail: Stock
Transmission: 1999 6-speed
Clutch: Spec Stage III
Rear end: Stock 4.10 Torsen
Wheels: 949 6ul 15x9
Tires: Hankook R-S3
Brakes: "Brembo" rotors, OEM pads
Suspension: Tien Monoflex, "Big" RB hollow front sway, RB sway frame brace and blocks, TrackDog adjustable endlinks
After about 2 hours of tuning on Saturday I finally got the ***** to get on it a bit and nearly **** my pants! Little over 1/2 throttle pull in second gear produced 13psi and a serious loss of traction. After more driving and one or two more heavy throttle loads I've got the highway and cruise tune dial in nice, just need a lot more fuel work in boost.
"Don't mean to sound like a queer or anything, but I love you guys." I might come across like a huge douche on this board quite often, and sometimes I am, quite honestly I'm humbled and very grateful for everyone on here. Without the vast amount of information in the wiki, archive, searchable threads, and people answering my idiotic questions this never would have happened.
In another 8 years I'll start on phase 2: Carillo 9:1 Pistons, Belfab h-beam rods, ID injectors, E85, Finish building manifold/downpipe, Garrett T2 framed v-band turbo.
Will post more pictures later, currently killing some time at the end of my day job..
Please allow me to step into the excuse zone for a minute..
I am a terrible welder, horrible fabricator, a master procrastinator, king of the unfinished projects, a jack of all trades and a master of none, and have my hands fairly full between working a full time job and attempting to rehab a house I bought last August. Bought my first and only Miata in 2005 for $3000.00 and have mostly enjoyed owning it with a dream one day of installing a turbo yet my quest has been full of fail. I've failed, my car has failed, and the world has failed. Three engines, one supercharger, and a lot of blood sweat and tears later, I can finally say "Success!" Well, Sort of..
On a random craigslist search for a GoPro Hero3 video camera I came across someone on craigslist selling what appeared to be an SSAutoChrome manifold and downpipe for $50.00 with the claim it was cracked in a crash. After exchanging some emails I met this homeless looking "drifter" dude (who had THE shittiest looking Laguna Blue miata I've EVER seen) and exchanged my hard earned freshly printed ten dollar bills for one cracked SSAutoCrap manifold and effed up downpipe. Quick phone call to my brother (professional welder by trade) and the manifold was drilled and welded back up however my turbo was incompatible because of the turbine outlet flange.. Mine is 4 bolt, the downpipe is for a 5 bolt. Long story short, ordered a chinacharger from ebay, cut the flange off and the downpipe in half, bolted everything together and tacked the flange and pipe back together in preparation for final weld. Naturally the wastegate tube on the downpipe didn't even come close to lining up with my Tial, so instead of doing what I should have and ordered an internally gated turbo, I cut the wastegate tube off the downpipe and assisted with fabrication of a new one.
Here it is, in all of it's
I had off Wednesday and Thursday (3rd/4th July) and put in 9 hours total between the two days working on installing all of my parts. Finally got to start it Saturday evening, verified the turbo had oil flowing, no coolant leaks, closed the hood up and went for a test-n-tune. Running Paul's Timing map (which might not be a good idea...) and started with the VE table from a similar turbo'd miata for a base.
Car: 1995 C-Package
Motor: Stock 1996, head studs and new gasket
Head: Stock 1995
Cooling system: Stock radiator, bad DIY reroute (Godspeed aluminum radiator on order)
Manifold: SSAutoCrack nothitblock model
Turbo: T3/T04E, .50 A/R Cold Side, Ind: 1.99" (57.75mm), Exd: 3" (73.55mm), Trim: 48.9, Turbine Wheel .63 A/R Hot Side, Ind: 2.56" (52.76mm), Exd: 2.2" (75.46mm)
Wastegate: Tial 38mm, 10psi spring
Intercooler: CXRacing 28x7x2.5 (Have a giant Vibrant to install eventually)
Plumbing: Flyin'Miata Silicone IC pipes
BOV: Ebay special that doens't work
Exhaust: "Custom" (lol) open downpipe, have 3" stainless Enthuza to install eventually
ECU: Megasquirt v2.2, HR10
O2: AEM UEGO
Ignition: Toyota COPs
Injectors: RC550s (ID coming in the future)
Fuel pump: Walbro 255lph
Fuel Rail: Stock
Transmission: 1999 6-speed
Clutch: Spec Stage III
Rear end: Stock 4.10 Torsen
Wheels: 949 6ul 15x9
Tires: Hankook R-S3
Brakes: "Brembo" rotors, OEM pads
Suspension: Tien Monoflex, "Big" RB hollow front sway, RB sway frame brace and blocks, TrackDog adjustable endlinks
After about 2 hours of tuning on Saturday I finally got the ***** to get on it a bit and nearly **** my pants! Little over 1/2 throttle pull in second gear produced 13psi and a serious loss of traction. After more driving and one or two more heavy throttle loads I've got the highway and cruise tune dial in nice, just need a lot more fuel work in boost.
"Don't mean to sound like a queer or anything, but I love you guys." I might come across like a huge douche on this board quite often, and sometimes I am, quite honestly I'm humbled and very grateful for everyone on here. Without the vast amount of information in the wiki, archive, searchable threads, and people answering my idiotic questions this never would have happened.
In another 8 years I'll start on phase 2: Carillo 9:1 Pistons, Belfab h-beam rods, ID injectors, E85, Finish building manifold/downpipe, Garrett T2 framed v-band turbo.
Will post more pictures later, currently killing some time at the end of my day job..
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