Hello from Orange County
 

Hello everybody,

My name is Jason. I've had my 90 smurf for several years now, and I have been fixing it up and giving it much love.

Anyways, I have always wanted just a bit more power out of the smurf. Cornering is a blast of course, but it would be nice to have some more fun in a straight line.

About the car:
213k miles, but perfect compression. Haven't run a leakdown test yet.
Completely gutted interior. No PS, no AC, no interior, no dash, etc.
Suspension, brakes, and steering system in good shape. De-powered rack, fresh shocks, fresh tie rods, etc.

About my goals:
I would like to add 40-50whp as cost effectively as possible. Cost and reliability are my two highest priorities. I have cash, but I'm not going to piss it away.
I have considered swapping in a 1.8 of course, though it seems that a BP-4W would only net me 20whp or so, and I'm not convinced it is cost effective ($/hp).
Since my power goals are obviously low, I am considering turbocharging the 1.6. I am completely aware of the fact the a 1.8 is a better choice for making power and spooling quicker.

About my abilities and experience:
I am a pipefitter and welder, so my fab and welding abilities are sharp.
I turbocharged an 89 CRX Si when I was younger. Used a T25 out of a Saab, cast manifold, custom downpipe, custom charge piping, DSM 450 injectors, DSM sidemount IC, Turboedit for tuning with a Innovate MTX-L wideband.
The point I'm trying to make is that I have the ability to fabricate and I understand what is involved with turbocharging and tuning a vehicle.

I plan on fabricating a log manifold, unless I can find a cast manifold for a good price.

It would be nice to hear what you guys suggest. Any used turbochargers that I should be looking for that I'm not aware of? I plan on picking one up out of a junked vehicle unless I can find one for a good price.

Also, if anybody has a suggestion for making 130-140whp naturally aspirated with a BP-4W, it would be great to hear. I would be surprised if it would be possible with a stock block, randall intake, exhintake, exhaust, and megasquirt tune.

I'm not dead-set on turbocharging, I just want another 40whp or so, as cost-effectively as possible.

The DIY FAQ and a few other threads have a lot of the information you are seeking.

Welcome to the forum.

You will have a bit of trouble only getting 140-150whp. Mostly because most wastage's are about 7/8psi and that will put you above your goal. You can build a manifold for about $150. Links to where I get flanges and such are in the DIY Fab section. Exhaust should be reasonably cheap since you can weld. You will need a wideband O2 and a MS. An older MS1 would probably work decently for you on a budget since you pulled all the creature comforts. Then intercooler will run you about $250-$400 to DIY.