y8s diy turbo update tease (updated!)
 

So I said it was time to break ground on the re-install of my DIY setup. Here's a couple teaser pics. You love my phone camera.

Stainless downpipe. Sitting on the old one. That's a 2" V-band clamp I think.
http://www.y8s.com/albums/turbo/DSC00169.sized.jpg

Turbo flange for dp. I closed off the internal WG port (the flapper's welded) and added an internal wall to improve flow.
http://www.y8s.com/albums/turbo/DSC00172.sized.jpg

Intercooler piping. All but the compressor outlet since that's gonna be custom. Throttle body inlet has fittings for BOV, air temp, and water injection.
http://www.y8s.com/albums/turbo/DSC00170.sized.jpg

Water injection bung with plug
http://www.y8s.com/albums/turbo/DSC00174.sized.jpg

BOV and air temp sensor
http://www.y8s.com/albums/turbo/DSC00173.sized.jpg

And that was my Sunday. Next I'll probably sort out the compressor outlet tube design so Bell can work on it while I reinstall the exhaust and fab up the downpipe.

Matt

wow thats coming out awesome.:bigtu: :bigtu:

oh and fyi, I didn't make the intercooler pipes. Corky did!

<--- jealous!!! those ic pipes are freakin nice!

Question about welding the internal wg flapper shut. Do you leave the flapper in and weld it in or do you take it completely out and fill the hole with weld? Also, I'm assuming you did the internal WG plug with stick. What type of stick did you use? Nickel??

Anthony

Everything looks good man, love the IC pipes. Is that a silver PC or paint?



I personally left my flap in because the flapper itself is the best fit for the WG port and two simple tack welds will hold it in place. I used a mig welder though so no idea about what stick to use. Might be able to just crank up the amps and use some 7018 on it. You're not really making a structural weld so I don't think preheating and nickel rod will be necessary. Cover up the turbine wheel when welding to keep splatter out of it.

LOL sweet, I can use mig with solid wire and 75/25 gas and it will hold?? How does that happen? We're welding cast!!

Anthony

That looks awesome! Corky rocks!

60AGS

I left the flapper in and did a couple tack welds with regular old mild steel compatible mig wire. Just remove the turbine housing first to keep the turbine clean.

The pipes are silver powder coat. I was expecting "silver" like with the sparkles and everything but Stephanie surprised me with these gems and I was quite happy. They have sort of a dulling polished aluminum look to them.

More stuff... from the installation of the intercooler.

I just tore off the front end.... it was easier.
http://www.y8s.com/albums/intercoole...0175.sized.jpg

pax side pipe. btw, begi sells some funky power steering line kit... they're VERY bendable. fit wherever you want. and I love zip ties.
http://www.y8s.com/albums/intercoole...0176.sized.jpg

throttle body inlet pipe. fits like a glove.
http://www.y8s.com/gallery/intercool...0177.sized.jpg

I guess the BOV goes here? air goes in over on the right.
http://www.y8s.com/albums/intercoole...0185.sized.jpg

Thank you for watching. Goodnight.

Goodness, what size turbo is that?

GT2876R. Half potato, half god knows.

its a big fucking 76 A/R (looks like 70 in the pics) compressor housing on a gt28 turbine housing looks like to me. That is a HUGE compressor. I would be interested to see how your spoolup characteristics are with that thing.

Looks good.. I'm v-band flanging all the exhaust this time around.. It looks baller, and it just works so much better..

I weld flappers shut with a mig welder.. Leave the flap in and weld all the way around it, I also tack the arm where the actuator attaches, just for good measure..

I would have gone with the GT2871R ... but good luck. Definately post up some vids ... btw doesn't the 76 have its own internal WG?

.70 A/R. Garret's naming system is stupid.

Back in the day when I got this thing, there were no fancy hybrid GT/T turbos. There were 2 GT25 turbos and that was it. The compressor is the TO4S. Here's the specs:

(table didn't work the first time)

For spool it's actually quite nice. Here's a shot of it at low boost compared to stock. Photoshop for the lose. 4psi at 3000 rpm.
http://www.y8spec.com/dyno/dynocomparo.gif

So for lack of a GOOD reason to switch (turbos aren't free), I decided to work with it and see what I could do with it. My favorite thing about this turbo? Garrett's website says it's not recommended for anything.

read above, no such thing back then. and yeah, it has an internal flapper... that's welded shut on mine.

It's not a 76 A/R, it's a 76mm compressor wheel (3.00 inches), garretts naming system actually makes sense.

Mark

I want your car :(

it sorta makes sense. it describes the turbine wheel and then throws some letters in there for good measure.

like GT used to mean "new aero, new dual ball bearings" but now dont mean shit. I see "GT" turbos with journal bearings and I go "huh?"

looks really nice, you need to crank the boost on that turbo and see what it can do!

whatever you say boss!!

here's the rough plan:

1. finish my downpipe (this weekend?) I just got more wire and flap wheels woohoo!
2. tweak the exhaust and add the MetalCat and V-bands
3. Find a place to mount a turbo outlet pressure tap. I suppose a drill and tap operation would work.
4. get Begi to finish my compressor outlet pipe
5. SLIGHTLY re-route the lower radiator hose to clear space for #1
6. run it on the stock ECU and datalog the fuck out of the OBDII port to characterise the stock car's timing, airflow, etc. for whatever personal reasons I want. (what, 150 rwhp?)
7. install the hydra and injectors, low boost (<200 rwhp)
8. install water injection and raise boost (>200 rwhp)
9. raise boost and break the motor (>> 250 rwhp)

it may not be a good plan but it is definitely A PLAN!

did a lot of welding today... no photos though.

But... the downpipe is pretty much done. just gotta add two sensor bungs. Unfortunately I didn't get to divorce the WG like I wanted to because it's just too tight with my manifold, but it's still ok. V-bands on everything now except the turbine outlet and wastegate. Should be a snap to reassemble and line up. 3 bolts basically hold my exhaust on. awesome.

oh and I also swapped out the rubber exhaust hangers for urethane ones. We'll see if that keeps motion of the pipes down.

ohhhh so big power is on its way. YESSSSSS

My intercooler is that size and I get amibent temps at TB.

Irronically, I was just thinking about the same exact turbo on my car... in a mitsu flanged exhaust housing though.. :)

Matt, your charge piping gives me serious wood.

I'm working on my car: 1990, 35k miles, with a BEGi IV.2 kit. I've just installed the FM happy meal clutch/flywheel kit, RC racing 550cc injectors, and I've ripped out the MSD box and AFPR in favor of a Hydra. I'm in the process of wiring it up, running sensors, etc. My kit is so old I had to get sensor bungs welded into the downpipe (WBO2) and throttle body inlet pipe (IATS). Also got FM's new intake and heat shield.

Here's my question. In the shot I've attached, you can see the turbo and some of the IC charge piping. I've got a little air filter looking doohickey attached to something - is that my BOV?

Again - Nice ride. I'm doing all my work myself but I'm hugely more impressed with the level of DIY you're tackling.

your car makes me feel all :pitlab:

yes

I got distracted today. Made some shiny things.

http://gallery.y8s.com/d/16887-1/DSC00213.JPG

I did weld in my O2 sensor bungs and mounted the exhaust mostly. Also assembled the turbo and WG to the manifold and attached the water lines and oil return line. So now I have this heavy octopus thing I gotta put back in.

Also rerouted the lower radiator hose. I had to clear out the space where the intercooler piping goes (between the ps pump and upper control arm) so the hose worms around elsewhere. Mcmaster has some sweet double barb fittings that work perfectly. And the NAPA by my work had some crazy hose that I cut up to get the shape I needed. Werd.

I think tomorrow I'll clean up a little. My garage is a friggin MESS.

Any new updates?

ok since you asked...

http://gallery.y8s.com/miata/turbo/intercooler/
New photos (reverse order fyi)

Since I don't use a BEGi manifold/turbo setup, I needed a custom compressor outlet pipe. I had Steph secretly send me a standard one to check fit and see where I needed to make changes. Also Corky is welding up one based on the Ghettocharger manifold/turbo position since he thinks it's pretty close to mine and markp left it at the shop.

You can tell it's PRETTY close except for 1) it's not 2-1/4" the whole length, 2) it's black, and 3) it runs into my sway bar bracket. Should be pretty simple to fix that. I could theoretically use it but it wouldn't be ideal.

2-1/2" turbo outlet, 2" pipe = CINCH IT = no.
http://gallery.y8s.com/d/16908-2/DSC00225.JPG

battle of the large diameter tubes.
http://gallery.y8s.com/d/16899-4/DSC00222.JPG

OH snap. I just realized I never got pics of the downpipe! Sorry guys. It's not all that exciting anyway. I can describe it tho.

stainless flange with the WG port welded shut
2-1/4 elbow to V-band clamp
2-1/4 transition to 3"
3" elbow to 3" v-band with two O2 bungs.
http://gallery.y8s.com/d/218-2/DSC00172.jpg + http://gallery.y8s.com/d/227-2/DSC00169.jpg

I love that 3 bolts hold my exhaust on. I think I mentioned that already. :)

I always love watching the builds come together. Seeing people do stuff themselves is really awesome. Here after I move into my new place, I will be purchasing a new welder, (yeah, I get to weld again), and start building my camaro turbo kit and a kit for my buddy's scion.

nice. if i had unlimited time, i'd boost every car i drive. :)

Isn't that the truth. If I complete the camaro, that will make my 2 cars boosted, and I am going to get a bike here soon and boost that also. Boost is extremely addictive.

:werd:

Update!

So I'm waiting on lower injector insulators (the head-side donuts) from Finishline and my charge pipe from BEGi, but I did some work on the car today.

I started re-adding vacuum lines for the wastegate and BOV. Exciting stuff.

I also did some work on my bumper. It'd had a hard life of flying gravel, removed front logos, and honda civic rear ends. I thought "what the hell" I can either replace it with a real paint job part or do it my damn self. As we all know people on this forum have taken the latter approach so I thought "why not" and started workin. I did some bondo repairs (85% job cuz I dont care) and sanded the whole thing down and primed it today. The last coat of primer is drying tonight and I'll finish sand it. It's a LITTLE wavy but hell I rammed a car with it!

Tomorrow I guess I'll finish sand and tack cloth and spray the first coat of black. It's duplicolor so who knows how it'll come out. I've got all sorts of sandpaper and rubbing compounds and shit.

What's left to do:
Install injectors (fuel rail, top half of mani...)
Finish vacuum lines
Install intercooler pipe
Finish bumper (optional!)
Reconnect injector wires in hydra harness (I had them run separately)
Reinstall Hydra + load maps + tune the mofo
oh and put my front wheels on.

Maybe more.

Pics tomorrow I guess.

you my friend...make me want to cry.

I just finished up a diy duplicolor front bumper cover (black). Those little-ass cans of brilliant black are good for about a coat. And do at least three. I polished through some areas just doing polishing by hand. Even so, it looks better than it did before. Good luck!

they only had one can :(

Guess I have to go back and find 2 more. damn. Or rock the primer and order some from paintscratch.com

what makes you wanna cry

PHO TOES!!!

Keep your turbo warm when it's cold out... the WOT special turbo insulator!
http://gallery.y8s.com/d/16914-1/DSC00239.JPG

These vacuum lines go in here somewhere....?
http://gallery.y8s.com/d/16917-1/DSC00240.JPG

Getting closer...
http://gallery.y8s.com/d/16920-1/DSC00241.JPG

http://gallery.y8s.com/d/16923-1/DSC00242.JPG

And the bumper:
Primed but not yet sanded...
http://gallery.y8s.com/d/16929-4/DSC00237.JPG

Sanded and wrapped up for the night to protect agains the squirrels.
http://gallery.y8s.com/d/16932-3/DSC00244.JPG

wow, looking great! that thing is going to be a beast. keep up the updates

bumper looks like a frog.
https://www.miataturbo.net/braineack/random/frog.jpg

^ that's awesome

so the "peppa" will be ready for May 12th?! Just needs to roll the dyno wheels, not pose.

when I saw the pic on my camera phone, i knew it was just a matter of time. those toobz are actually future surround sound speakers.

may 12th is the only date on my mind. sorry mom.

pepa, with one p?

:rofl: at avatar.

well, that's your call:
hold true to the salt
or true to the peppa

dr. peppa?

update number eleventy-four and a half...
 

Today I....

800 grit wet all up on the bumper. two coats is lame. If you're going to paint a bumper, get 3 LARGE cans of the spray paint. and 3 clear. bah. Dont say anything when you see where I sanded it through. I didn't feel like fixing it. Not worth the time. I then sprayed on 2 coats of clear. It has some shine but definitely needs the overspray sanded out and lots of rubbin' out. No rush. I'll probably run it this way for a few weeks and then do that work. Gotta dyno day to prep for don't ya know.

Eventually I think I'll have a new bumper drop shipped to a paint shop or something. EZ.

I also reinstalled the Hydra. The injectors went in yesterday. I had to reconnect a few wires from some "customization" i did, but that only took the few minutes between clear coats. All buttoned up.

Now for the suck part. Leaving my battery connected for months has turned it into a giant, very heavy, paperweight. Thank gourd for warranties. Gotta find the receipt!

until next time.

yeah I had to replace my battery after the diff & clutch install. good 'ol Brown's Mazda handed me a new one with a reciept.

the autozone by my house has 3 in stock and offered to test (ie waste my time) mine before exchanging it for me. 8 year warranty and it made it less than 1. next time I unplug or leave it on the charger, save myself some hassle reprogramming my EDFC, Defi Control unit, and stereo presets!

I bought my in Oct, Lasted 5 months....Mazda battery :gay: was unplugged, tested bad, made getting MS hooked up a pita, had to keep the thing jumped on my altima the entire time.

OK so I got the car put back together, the hydra installed and updated, and holy smokes she fired up on the first try.

After fixing a minor water leak (clamps not tight) and minor oil leak (Defi sender is 1/8 NPT, not BPT--removed the adapter), the car seems pretty solid.

So I guess next is fixing up the front shrouds and putting the wheels on and .... (I know this is crazy)... driving it.

more to come.

sweet! lets race.

Damn, that's a big turbo, I was thinking about getting it, should get you into 350whp range. Your projects' looking good, get it running I wanna see some dyno numbers with that turbo.

he's going to the dyno day with the crew on the 12th.

I got distracted. But did the front undertray (weak, must redo this at some point). Put the wheels on--need to lower it and torque em down.

The distraction was painting the part of the bumper that covers the space in front of the radiator. It WAS silver but while painting my bumper I didn't bother to mask it so it was orangeprimerblackbutwithsomesilver showing. So that's taken care of.

I also made a new panel for the trunk to fit over the spare tire well. Not sure why, just did.

And i'll be damned if the bumper didn't turn out fantastic. Just over a week of work and it's shiny again. I've got pictures somewhere.