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DIY Turbo Discussion greddy on a 1.8? homebrew kit?

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Old 04-16-2008, 08:41 PM   #1
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Question The story so far.....

Ok, after a long period of waiting, browsing, coaxing and multiple strokes of luck, I have been able to put together most of the parts I need for my build. For the record, I have been trying to design a system which:

1) Fits my budget (https://www.miataturbo.net/forum/showthread.php?t=16063)
2) Fits my needs (https://www.miataturbo.net/forum/showthread.php?t=16685)

Since both of those were, IMHO, not typically available in a pre-fabricated kit for the Miata, I decided to go the DIY route. Another reason is that creating stuff is my draw. In keeping with most projects I've done so far, I decided to not simply copy what several people before me have already done.

So, finally, my search for parts constituting the perfect system has ended. Here's the result:



I'm looking to make only about 175 whp but with awesome driveability. Essentially the goal is to make it feel like a big V6, much like my other car, a Jetta VR6 (whose throttle response I love but handling I loathe like the plague).

So far I'm out about $600 on these parts alone. The MS ECU and wideband are already dialed in pretty well for the stock engine. The injectors are going to go in soon after they're back from Rehab. I'm looking to start the actual build around the end of the month.

Please feel free to comment and give me any suggestions for improving this further.

Special thanks to Devin Mac. If it were not for him I probably would have stopped the project.
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Old 04-16-2008, 08:50 PM   #2
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More detailed pics! I'd like a few of the manifold and any other details you care to share about it. I'm considering building one of their kit manifolds.
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Old 04-16-2008, 10:06 PM   #3
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Very interesting collection of parts - should get you what you want. Did you see the high flow cat in that position on another Miata? That's gotta be a tight squeeze and I know the cat needs good airflow.
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Old 04-16-2008, 10:12 PM   #4
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Didn't know ETD made DIY manifolds for you to build. I'm already using that same turbo but with a BEGi T3 manifold with a bolt on adapter plate for the subaru flange. I would like to know some details on that downpipe though! Also, looks like you still need to clock the turbo and don't forget that that turbo will need an inline oil restrictor. The stock oil lines that go to the banjo bolt has one built in, so assuming you are running either a -4AN or -3AN line, add a restrictor (I used a pop-rivet head). The turbo itself is great, loads of torque down low, but definitely runs out of steam on the top end. I think I may be upgrading to either a VF-39 (STI turbo) or a 16G off ebay. Good luck with the rest of your build!
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Old 04-16-2008, 10:41 PM   #5
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I don't think those injectors are going to be big enough to safely support 175whp (without raising fuel pressure).

I'd recommend getting some 460s, they will be plenty big (but not overly large) for your goals.
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Old 04-17-2008, 01:04 AM   #6
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Some more pics of the parts:



patsmx5, are you referring to the JGS manifold? ETD does not make custom manifolds or even sell a kit anymore, even under special request. This one was sold to me by Starsky (thanks j) who got it made 3 or 4 years ago. I'm happy I could lay my hands on such a high-quality and rare piece. Its probably miles ahead of any other mass-produced manifold.





I should have been more clear, the downpipe is actually a japanese aftermarket part meant for the STi. I got a good deal on it so grabbed it for the flange and the OEM-quality metal-core cat that's on there. I doubt it will fit any miata because of its girth and the wrong angles (in Subarus the turbo sits at a slight fore-aft angle).



The base of the entire build. Got it for really really cheap, it had only like 45k on it, zero play, no oil anywhere, and so clean I could eat off it.



The funny downpipe flange.

Important thing to note: This is NOT the 02-05 WRX turbo. Its from the 2.5L engine, which are all post 06. Apparently the turbine housing is larger than the 02-05 turbo. But even if its not, I doubt I'll be exploring its limits soon.

karter74, what should be the ID of the oil-inlet line? Isn't just -3AN line small enough?

The injectors, yes, the duty cycle will be close to 90-95% at that power, but is that a cause for concern since I'll be rarely hitting peak power? Maybe I should think about setting my base pressure a little higher, like 60 psi.
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Old 04-17-2008, 01:12 AM   #7
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Whoops, yea I meant the JGS manifold. You parts look good for the budget.
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Old 04-17-2008, 08:11 AM   #8
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Quote:
Originally Posted by Efini~FC3S View Post
I don't think those injectors are going to be big enough to safely support 175whp (without raising fuel pressure).

I'd recommend getting some 460s, they will be plenty big (but not overly large) for your goals.
even with MS?
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Old 04-17-2008, 10:13 AM   #9
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MS can't make small injectors inject more fuel than they can actually supply.
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Old 04-17-2008, 11:24 AM   #10
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Those injectors will only work if you raise your fuel pressure or run about a 95% duty cycle, 80% is suggested max..

If you bump your fuel pressure to about 55 psi at the rail you should be fine.

you would be better off with any of the injectors below..

Mazda RX8 420cc - Yellow Body #195500-4450
89-92 Toyota Supra 7MGE TURBO 430cc – Black Top
89-92 Mazda RX-7 NA 440cc - Blue Top #195500-5740
89-91 RX-7 NA 460cc - Red Top #195500-2010

your injectors would work really well for someone with an NB and those HP goals.

Last edited by MX5-4me; 04-17-2008 at 11:41 AM.
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Old 04-17-2008, 11:59 AM   #11
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with that size turbo and his power goals, hell be fine. I ran my 305s at 95% DC at around 7psi....which was about 170rwhp. If they aren't enough, he knows he can bump the fuel pressure or swap them out.
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Old 04-17-2008, 12:01 PM   #12
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he should be ok

nice collection so far pipe, you are almost there
how do you plan to route your IC piping? do you have AC and PS? if not clock turbo down and run your pipe around the rad.
good luck, post pics
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Old 04-17-2008, 12:31 PM   #13
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thanks everyone for the inputs.

i am planning to ditch the MSM intercooler and go with a MX6-T intercooler, with an under-the-rad setup. Just for the simplified routing, and more importantly, less money for couplers and T-bolts.

Also I will probably go with a stock MSM exhaust for maintaining that easter bunny stealth. What do you guys think of the stock MSM exhaust? I've been told its good enough for 200 whp.
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Old 04-17-2008, 12:33 PM   #14
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it's ***, you need 3", it's like crack, you have to have
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Old 04-18-2008, 03:10 PM   #15
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3" for a sub-200 hp car sounds like overkill, doesn't it?
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Old 04-18-2008, 03:21 PM   #16
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never. improved efficiency.
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Old 04-18-2008, 03:22 PM   #17
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damn, you always beat me to it
3" or go home
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Old 04-18-2008, 03:38 PM   #18
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sweet action. glad to see this is coming together!

i'm with Brain on the injector thing. I'm maxing out my 305s at about 8psi @ 6500 right now, where it puts them into the 90'ish % range for DC.
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Old 04-18-2008, 05:39 PM   #19
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thanks man.....and for the record, I owe you one for helping me out!

I need to think hard about the exhaust, as that seems to be the only missing piece of the puzzle.

Options are:

1) stock MSM (only cause I hope to bag one on the cheap)
2) 2.5" / 3" (whatever is easier) dp, cat, and summit glasspack with a downturn. My only concern is it'll be too loud with this setup.

Any other ideas?
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Old 04-18-2008, 05:59 PM   #20
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I can get more of that ETD Shorty with a WRX flange, but it would involve 5 people to be interested and paid to get them produced. Just incase a bunch are interested.
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