After 2 days of seriously hard graft and lots of unwanted problems with missing parts and lack of information i have finally got round to get the pictures up of the build.

After putting it all togeather with a full service, i turned to key and it started first time with no hesertaion to my surprise, although unfortunatly the exaust is blow quite badly where the turbo downpipe connets to the lower downpipe.

Which i was told by begi self seals. so the next thing is to try and get a clap round it somehow and hope it works if not its a hell of a job removing it again.

Anyway here we go....

I began the build on wednesday firstly putting the car up on Four jack stands with the aid of Daveyf's jack (thanks Dave :wink: ) then removed all the exsitign parts from the engine bay ready for the turbo install; downpipes, airfilter asembly, inlet piping, etc.













After spending an hour looking over the instructions and under the car for the correct place to drill the sump i then realised that with the aircon system and power steering i couldnt drill where was asked so without mucking around i decided the best thing to do was to call begi in texas.



After explainign the situation they then said i could drill in a different location towards the front of the sump. I marked the point of penertration and got out my small drill!
Because of the different sizes in threads from american and english i had to buy several different hose barbes in order to get the best fit.
This then allowed me to use british pipe thread instead of the american nation pipe thread.
After finished the sump and draining the oil while running several pints of oil throught the new hole to clean out any smal lmetal shreads fro mthe drilling i head wrapped the water hosed on the firewall where the turbo would eventually be sitting in front off (it goets hot dow there ya know :twisted: )





After this i began prepearing the turbo attaching all the relivant attachments and hosebarbs when i finaly came to fit the signal line for the wastgate only to find the hole which was sposed to be drilled and threaded was not there.
After speaking to begi again and them appoligising once more i had to call it a day, and go and get the appropriate drill bits and taps the following morning.

DAY 2.............

IT started off slow but it came togeather slowly but surely. i started to realise just how difficult this job is when you take in to concideration how awkward all the fittings and nuts are for all the turbo attachments.





Because of the set back the following day i decided to take the opertunity to paint my cam cover.
After fitting it all back on the car it started to look alive. All the turbo water and oil lines went on even though they were extremly fidderly to route and fit, and the fuel pressure reguator wasnt quite as dauntign as i thought to fit. Although there inst much space to fit it agains the firewall.











After a hectic day i managed to finish the installation and refill the car up with all its fluids.
I decided it was probably best to fire it up as to prepear for the next days final jobs, and to my amazment it fired straight up, but unfortunatly sounded like a spitfire on heroin with the horribly load blowing turbo downpipe, so didnt realy get a chance to here the turo spool up as yet, but tomorrow is another day.

fingers crossed i managed to get it all sorted and ready for the test drive, just hope i dont have to adjust the timming as i havnt a clue how to do it.

watch this space 8)

 

Very nice! What turbo is that? What are you using for engine managment or is the afpr it? Awsome progress, keep the pics coming.

 

its the bigi shanghai kit, just using the begi fmu for now untill i can afford a megasquirt, then ill turn up the boost, but just gunna run at 6psi i think, as long as i get the exhasust sorted.

 

no o2 clamp? you at least need an o2 clamp with that fmu.

 

Iv got the stock o2 sensor installed.

 

i love the curb side install.

 

i dont think the naighbours where to please.

 

If you install a prop on the front you might be able to make it fly. You already have wings!

 

haha, yeah ill bear that in mind, thanks for the idea

 

I think so.

 

im not talking about o2 sensor, im talking about an o2 clamp

 

Everything except the eyebrows

 

irish racing green?

 

Doo iiittt, take a pic and tell the asian lady at the eyebrow place, i want those eyebrows..

 

wow mad props for doing the install on a public raodway. you have skils. What are you doing for timming? WI

 

Ill probably end up adjusting it slightly in accordance with begis write up but first things first i need to stop the turbo down pipe blowing and its in the most awkward place, typically not under the car but right behind the engine with no access.

 

Damn your ugly! On the other hand pretty cool build, I bet you can't wait to test drive it

 

Haha "hey look his brake booster is on the wrong side of the car" :P

 

You need to shield the washer bottle and the low pressure A/C pipe from the heat of the turbine housing.

You will probably also really need a device to retard the timing as you gain boost pressure. A Bipes unit perhaps.

I also recommend an O2 clamp. It is important.


Good job and good luck.

 

Thanks for all the friendly posts.

I spent yet another day on the car, and to be honest not getting very far.
I started out very ealy in the morning (student time) 11.30am and began to tackel the situation of the blowing exhaust.
First of all in order to get the downpipes to fit togeather snug, a long slim bolt attaches to both and a small lock nut is provided.
A lock nut is an understatement, more of a, 'im not going to do up more than two turns' nut.
After gettign a lift into uni i made up another bolt without the use of the stupid none moving lock nut and went home and attached it.
After getting it to a resonably tight fit i thought better safe than sorry and decided to tighten it a tad more..........typically just on that quarter of a turn which didnt take much effort, Twang. another snapped bolt.

Running out of patians i took the whole lower downpipe off went to uni again and cut four slits into it then on my way home went to a very friendly exhaust fitter who surplyed me with some clamps free of charge they even squirted some special exhaust assembly silicon into my pipe. not bad ay!

after arguing with the pipe for another hour or so and maganing to tighten the clamp in the tightest way they could make it, i finaly got ready to turn the key, thinking to myself this is it....its turbo time.

But no. :***:

The Exhaust manif old was blowing like a honey prostitute on heroin, but making alot more noise.

After spending the entired after noone tightening and loosening the manifold i had no luck.
in order for me to get it to fit properly, im going to have to deassemble the inlet piping and remove the turbo from the exhaust and manifold then remove the manifold and drill out the holes in the exhaust manifold as they are to tight.
When putting the manifold on i had a real struggle getting it to fit so i guess i will have ot take it to uni, but unfortunatly i wont be able to get this done untill next week as i have family commitments this weekend.
So i didnt get to drive it...............................well actually im lieing about that bit.

After all the disapointment i went of the final checks for testing and bit the bullet put it in gear and decided to take it up the road with the exhaust headers growling horribly at around 3-4000rpm the turbo kicked in and my god what a fantastic feeling!
after a quick drive up to the roundabout and back i called it a day.
Although disapointing and extremly hard unexpected set backs in almost every area mainly due to manufactures faults the first feeling when the turbo kicked in took all the pain away and at that point i realised its going to be worth it! 8)










i jsut need to get the exhaust sorted, timming oh and get my head around the boost gauge. :?