1g Talon Super HX40/HX35 Hybrid build

Posted by apedog, Mar 9, 2012
DSM Build Journals - Start a Journal to document your DSM build and document race events, dyno days, etc for the car.

  1. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    SCROLL DOWN FOR NEW UPDATES!
    SCROLL DOWN FOR NEW UPDATES!
    SCROLL DOWN FOR NEW UPDATES!



    So everyone I've decided to go with a big turbo setup. The mods I had on it were a Small 16g, PTE 680cc injectors, Ported 2g exhaust manfold, Ported Evo o2 housing, 3" turbo back, Ported gasket matched on the intake side on the head, Walbro 190lph fuel pump and DSMlink v2.

    Well my transmission blew up and thats what started it all. The plans I have for this car now is to make 350 to 400 horsepower so I figure an hx40 could easily get me there plus it was inexpensive for how much power it can make.

    I just bought an HX40/HX35 hybrid today. Now the guy I bought it from didnt even realize it was the "super" hx40 wheel until I got there which was kinda cool. It was never ran on a car because it was rebuilt so I have to get it balanced. No biggie:thumb:

    Also got some KYB AGX's for the rear so gotta put them on too. My rear struts were so bad that any bump I hit felt like you were in a damn rollercoaster because it bounced so much :cry: Also Eibach Sportlines which will lower the car 2".

    Still gotta get a fmic, fuel pump setup, manifold, wastegate, injectors, and an fpr. I would like to get cams and im sure I will but that will probably be later.

    Now obviously im not new to dsm's but putting this huge turbo in my car is kinda intimidating so any feedback would be nice too :D Id like to finish a journal and hopefully take this car to some meets:hellyeah:

    Heres how it sits now.

    Attached Files:

    Last edited: Oct 15, 2012
    #1
  2. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    UPDATE 4/18/12

    Bought some things and only need a few more to go.

    Punishment FMIC
    BEPDSM7 manifold flanged with 38mm wastegate
    Synapse Engineering wastegate
    4" intake pipe
    2g mas
    SX AFPR
    1000cc PTE injectors

    Deleted all emission vacuum lines and made an egr blockoff.
    Also deleted the AC.


    [​IMG]
    [​IMG]
    Last edited: Apr 24, 2012
    #2
  3. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    UPDATE 4/22/12

    Just found a welder that is going to weld me up a twin scroll manifold and o2 housing which is REALLLLLLY nice! Hx40 power with hx35 quickness AND twin scroll? This thing is gonna spool so quick!
    #3
  4. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    UPDATE 5/15/12

    Finally got some progress done.

    Installed my SX Racing AFPR
    Tranny installed..again..LOL

    Still in the designing process of making my twin scroll manifold but it WILL be done. Just got all the parts today. Ill have plenty of pictures when that is ready to go.
    #4
  5. silversgst

    silversgst Proven Member

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    Any updates?? Interested on how the twin scroll and the o2 is gonna be.
    #5
  6. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    UPDATE 6/21/2012

    Got the manifold welded up but im still waiting on wastegate flanges to get here.

    I decided to run speed density so I sold the 4" intake and the 2g mas. Im not sure if im going to buy another pipe with an air filter on it. Im runnin low on money so I might just throw the filter directly on the turbo until then.. LOL

    I found out the upper intercooler pipes I bought from a member on here were for a 2g so I had to take them off because it definitely wouldnt fit. Hopefully Im getting a Synapse Engineering BOV welded on a pipe made for a 1g here soon so thats not too bad and a throttle body pipe. The intercooler that came with it was a punishment intercooler


    Heres a test fit with the turbo in the car
    [​IMG]


    To be completely honest though I have never welded pipe before so the manifold dosent have THE best welds but I dont think I did too bad. We'll see.

    If all goes well I should have all the parts I need to finish the car by next week and I'll be able to start tuning. Ill be posting a lot more pictures now that I have the ball rolling.

    Still have to get another wastegate, o2 housing, and upgrade my ecmlink to v3 because I have v2 still.
    #6
  7. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    UPDATE 7/8/12

    So just finishing up the project now. I bought my other wastegate and flanges and welded them on. My friend described my engine bay as a frankenstein invention haha I must say I agree with him.
    [​IMG]
    http://sphotos.xx.fbcdn.net/hphotos-ash4/376242_10151878356230058_583789692_n.jpg

    Also for the oil drain I figured out a REALLY easy solution for holsets. Get a 1/2" NPT Billet oil drain flange. Go to advance auto and buy a 1/2" heater pushlock piece for $5 and cut a 2g oil return line in half and put that on the pan. Its WAAAAY cheaper than what some of these sites are selling for like $100 bucks. Yeah right. I probably spent about $45 and its perfect.
    http://i56.photobucket.com/albums/g186/cletus1234/20120708_071742.jpg

    I did end up buying a synapse bov from a member so im really excited about that.
    [​IMG]
    Also I got ecmlink upgraded to v3 lite because of speed density. I still have to get the bung welded in for the iat sensor.

    I am also going to switch the wastegates around so that the pipes go through the hood and are a little flush. I wasnt to fond of the idea at first but I saw a couple videos with it done and now I think its pretty cool. Plus LOUD haha

    For the o2 housing, I actually bought one from a website that custom makes them. Its in the mail now but it looks like good quality.
    Turbo Elbow Outlet Mitsubishi Eclipse & Talon DSM 1G 2G O2(T3/T4 5Bolts Flange)


    So all in all the car should HOPEFULLY by saturday of this week.
    #7
  8. apedog

    apedog Proven Member

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    Just got my o2 housing. Its actually really good quality, im impressed. I havent mounted it yet but when I do I deffinetly have to modify my downpipe to fit it. Ill have pictures of the downpipe later.[​IMG]
    #8
  9. NOMIEZVR4

    NOMIEZVR4 Proven Member

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    Bump... any updates??
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  10. apedog

    apedog Proven Member

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    Lewisberry, Pennsylvania
    UPDATE 9/12/12

    So I havent posted in a while because I started college and really havent had time or money to finish the car. My dad decided to help out with the build so here it goes.

    I threw out the manifold I made because I suck at welding. Short sweet and to the point.
    So I found a new manifold in the classifieds. Its a t4 twin scroll with one wastegate and im going to adapt it to my t3 with an adaptor. Ill have pictures soon
    #10
  11. Mishimoto

    Mishimoto Proven Member

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    Looking forward to the pics! Welding skills will come with practice, stick with it. :thumb:
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  12. silversgst

    silversgst Proven Member

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    Where did you get the 5 bolt 02 housing?? Looks really good, mine didn't look to good :D UPDATES LOL
    #12
  13. apedog

    apedog Proven Member

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    UPDATE 10/15/12

    Sorry its been taking so long guys, I've been in college and could only work on my car on the weekends. Good news though the car is running and driveable!

    I recently bought a custom t4 twin scroll manifold from the classifieds but needed a legit adapter to attach to my t3 hx35 housing. I looked for a while and found a REALLY nice cnc machined one on eBay for around $50.
    [​IMG]

    What I did not realize though about the manifold was that the flange was crooked so the turbo sits out more towards the passenger side of the car which is actually pretty cool. I just had to factor in I had to make a pipe run from the turbo to the downpipe now that it was more away. I also had to extend my intercooler pipe and make a new oil drain.
    [​IMG]
    [​IMG]

    For the oil drain I just used to 2g oil drains connected with three hoses. Really simple actually. I dont have a picture of it at this point. Will get one soon.

    To connect the downpipe to the turbo I had to extend my downpipe about a foot. I used the ss o2 housing I mentioned before in the either post by cutting off what I thought was the same pattern flange. I bought a 2.5" pipe and welded basically a mini downpipe to the main downpipe. Ill have pictures of this then.

    For the intercooler pipe I just bought a foot long straight aluminum intercooler pipe, cut it to size, and just clamped it up with a coupler.

    Im still working on getting slim fans but the car now has an idle tune and a cruise tune and my god it sounds so good haha The turbo starts to spool a little before 3k but its also not tuned for wot yet so that number should go down a little. Ill have GoPro video soon as well as a recent picture.
    [​IMG]

    The mods as of now

    HX40/HX35 hybrid turbo
    PTE 1000cc injectors
    SX Afpr
    Synapse BOV
    Synapse Wastegate
    Punishment Intercooler
    EcmLink v3 lite
    Speed Density
    Walbro 255hp
    Aem wideband gauge
    Aem boost gauge

    What I still need-
    Slim fan(Ordered and on the way)
    A new AEM wideband sensor.
    New flexplate bolts(mine keep coming loose)

    I bought it off of eBay but unfortunately it didn't work LOL The plate that would atatch to the turbo housing is not even close to being the right size LOL I ended up cutting that part of the o2 housing off completely, welding a straight pipe to it and and then welding it to the turbo vband part.
    #13
  14. Mishimoto

    Mishimoto Proven Member

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    Great update! Nice work.
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  15. apedog

    apedog Proven Member

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    UPDATE 10/23/12

    So my slim fan came the other day along with my wideband. I ordered ARP Flex plate bolts so they will probably be here sometime this week.

    However I found a DEAL with my wideband sensor. I was searching around and found a guy on a honda forum that was in the same position to buy a new sensor and he found the exact part number that aem uses with bosch. Just so happens that advance had these sensors for $63 so I went and picked that up. The ends of the sensor do look different so that kind of scared me since aem claims they specifically make theirs for the gauge. However when I installed it, it reads perfectly fine.
    [​IMG]
    [​IMG]

    The fan I ended up installing in the front of the radiator instead of near the manifold because the manifold ended up melting the top of the fan LOL I had to reheat the fan to melt it back to the point where I could use it. Im deffinetly gonna need two of these fans because I get A LOT of heat from the engine bay but one fan will do for now cause of winter.
    [​IMG]
    [​IMG]
    Last edited: Oct 31, 2012
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  16. davidaus

    davidaus Proven Member

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    what fans are those? looking fancy haha
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  17. keveka2

    keveka2 Proven Member

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    nice work looking forward to whats next
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  18. apedog

    apedog Proven Member

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    haha nahh they're just cheapo 12" red eBay fans. Actually pretty damn good for like $30:p Im probably gonna end up buying another one when summer rolls around just because its hotter but it will do for now since its cold.

    Im gonna end up posting some logs here soon. I only have it around 11 psi now and its feel really nice. I found that I am going to do the Excel method to fine tune with my WOT pulls because to be honest im not a guru with ecmlink so im not sure exactly what to look for. Tuning is relatively new to me
    Last edited: Oct 31, 2012
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  19. apedog

    apedog Proven Member

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    UPDATE 10/31/12

    So instead of buying a dump tube for the wastegate, I decided to make my own and it came out pretty decent. I dumps right where the downpipe curves to go to the back of the car.

    Im kind of worried about the heat from the dumptube so I sprayed the pipe with hi temp 1200 paint.
    [​IMG]

    So I took the car out to test how the heat would be this happened.. The crank pulley destroyed itself
    [​IMG]

    I ended up buying a nice one piece crank pulley to replace it. I havent got it yet so I cant take a picture of it.
    Last edited: Nov 2, 2012
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  20. Mishimoto

    Mishimoto Proven Member

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    Dump tube came out pretty nice.
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  21. jksmith

    jksmith Proven Member

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    looking good keep updates coming
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  22. apedog

    apedog Proven Member

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    UPDATE 11/18/12

    Not much happening right now. Ive been trying to source and get rid of my oil leaks and so far so good. I found out the nut that is on the oil pump sprocket came off so luckily nothing happened. I got a new nut and loctited the sh** out of it so it should be good now. My other leak was coming from the adaptor for my oil feed line. It was stripped out so I have to get a new one now. Also my valve cover had a crack in it and was leaking, I tried to fix it but ended up making it 10x as worse so I have to get another one.
    #22
  23. apedog

    apedog Proven Member

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    UPDATE 11/21/12

    Picked up a Hyundai valve cover yesterday. Only difference is that I have to get new outer bolts because the outside bolt holes are thicker.
    [​IMG]
    #23

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