Meanwhile in Czech republic/2013 Holset HE531VGT 2G AWD build

[MarsaGSX]

Hi All

Thought I could share my build with you guys . Never seen anything that BIG in 2G engine bay
As every year..Iam changing again my setup..
Last year found thread about guy which put holset HE351 VGT and spooled 35psi at 3500rpms or something.. that way I thought umm find bit bigger VGT and this could be pretty impressive.. Maybe two months later found on ebay Holset HE 531VGT and I was sure this is my way threw 2013 seasson!

Specs:
2G 95 AWD /MT/6Bolt
Engine was built by me at 2008.
2.0l 6B Mahle/eagle/ FFWD cryoed,micropolished,ballanced oem STD crank
ARPs/ Cometic
Topline front cover and water pump.

Head
-Kelford tx272/FP beehive springs, EVO alu retainers,other than that stock 6B head.3angle valve job,custom built Intake manifold-5l plenum,120mm runners,Velocity stacks-Q45TB

Forced induction
-Holset HE 531VGT, custom built Top mount ex manifold,single Tial 44, 3.5" turbo -back
2.5" Lower IC pipe,3.5" BEP front mount/short route, 3" upper IC pipe, Tial BOV, GM IAT,custom ISC housing,Omni4Bar Map

Fuel setup
Wally intank/6an to 5l antisurge tank/ 2x 6AN to 2x Bosch 044pumps/8AN to Golan filter/8an bung welded on Stock rail/ Bosch 2200cc high Z inj/Aeromotive FPR/6AN return to antisurge tank. interconnecting between antisurge tank and stock tank.


As for HE531V.. Is basically HX52 comp wheel 65/98
exhaust wheel is 86/77 with huge VGT ex side/ 280mm Outside "diameter" That way first I did was cut out radiator wall..the "rung" so I can move my radiator bit "out" Next removed front tranny mount to fit my collector
Then simple start to fab collector and then whole top mounts.. spent 2/3 weekends of work. 4x we started from zero..cus the design wasn´t idela to get all runners equal.. finally my runners are from 650mm to 670mm which is great Then I just waited for week for my TIG welder. Later I spent 9hrs of hand grind my turbo flange.. My TIG welder just did not tightenede ex side to flange during welding .. and since the flange is in baaad position.. my machinist couldn´t put on milling cutter to straightening..

After heat wraping and bolting on ,started with fabing actuator for VGT(MHI intarenal wg/actuator) removing Oil Pan to bore 18mm ID for oil return line, new water lines for turbo, Lower IC pipe, changing Inlet in Water rad and milion other small bits..

Then built exhaust ..3.5" downpipe. Its not best to do this with car only on jack.. so small space when you on lying on your back on the ground and oil pan touching your potbelly

for turbo´s safety put on oil feed line oil press probe

First drive was WTF she won´t spool at all.. 15psi at 6200, 30psi at 7200rpms/ I had still my 60mm Silencer in muffler.. removed him and spool went down to 15psi at 5200 and 30psi at 6200 rpms, then found two Bigger boost leaks and spool was 300rpms faster.. good but still not the area where I wanted.. Expected 15psi at 3500-4000rpms.. Finally after watching Formula1 race in Bahrain.. thought I should simple fix my VGT in Closed position.. I controled my VGT via MHI internal wg actuator..which have 11psi sring.. so once she spooled to 11psi VGT opened and spool up slowed.. Once I fix my VGT in closed position I reached 15psi at 4200rpms(same as my BW s366 0.91ar) and 30psi at 4600rpms!!! (s366 was at 5200rpms) the turbo is blast..
Wthin 2-3weeks going to dyno to find which VGT position is best for efficiency.. Iamnot looking for fastetst spool up possible.. but for best mid torque possible.. wanna see cry 16G guys

Enjoy

 

[johnmel]

damn man this is awesome

 

[Boosted6]

Badass ride.

 

[biglady112]

I am glad things are coming together Venca. Send me some more datalogs as you keep making progress. The last round was was starting too look really good.

 

[92AWDHX40]

Sick build love work more pics.

 

[ncdirtrider249]

Holy shit!

 

[danielsl1999gsx]

How does this manifold not fall apart under full boost? That turbo looks like it weighs a ton!! Badass either way

 

[MarsaGSX]

I am glad things are coming together Venca. Send me some more datalogs as you keep making progress. The last round was was starting too look really good.

Thanks a LOT MAN!

Steven is the man.. thanks to him I was able dialed in my Bosch 2200ccs/basically he told me what is messed up with my link setup.. way back downloaded someones settings for cold startup on E85(had problems catch up on E85)..tried lotta things.. and later Steven found all those settings only slow down and meswed up my ecu.

Thanks Steven


BTW... Almost forgot THANK few guys which helped me...shared their knowledge and spend their time to help me

-biglady112 thanks for helping me with settings/tune and answering milion questions all around! This guy replied every single email! great guy

-Brian ERB Thanks for sharing your knowledge about building ex manifolds!

-Drew Jones answering my questions on FB..

Thanks all

How does this manifold not fall apart under full boost? That turbo looks like it weighs a ton!! Badass either way

turbo weights almost 60LBS! only ex side is 22lbs..

I just braced her against tranny/you can see the brace on manis pics.
Secondly my tubing is not sch10 at all.. sch 10 is 0.109" thick..(if rememeber correctly) mine is 0.118" thick

Pushing 30psi right now and looks okay..



Finally my dyno session should be within 20days.. I would like to dyno her much earlier.. but I don´t have driver with licence to tow trailer w car.. need to wait

Today fabricated VGT stoppers.. did 4 stoppers with different lenghts.. I can change on dyno to see what VGT position is most powerfull
Going to push her to 36psi of boost to see how she performs my Target is 800EUspec crank horsies

Thanks all guys


Venca

 

[enos1010321]

One snail to rule them all!

looks incredible, you can really tell you took your time in there was a lot of effort involved

keep the updates coming I'm subscribed!

 

[cruzanspeed]

Beast build!! Damn nice... I'm building a supra with hx52. It should be fun

 

[MarsaGSX]

One snail to rule them all!

looks incredible, you can really tell you took your time in there was a lot of effort involved

keep the updates coming I'm subscribed!

Thank you for the kind of words Sir! Was lotta hard work, lotta headache.. and hopefully dyno session will be "cherry on the cake"

 

[Boostdriven]

Very impressive, 30 psi by 4700 rpms for a turbo this size is just badass, you should be proud of yourself I noticed on the picture of your log the timing is only at 10 degrees, I think you can raise that up a bit, it might spool that turbo even faster and make the car a bit more responsive in the low end. PM me a log and I'll take a look at your timing settings and see if I can make some adjustments for you. If you have any questions never hesitate to ask, you have my attention and respect.

 

[MarsaGSX]

Okay, some update from 2012..
Intake manifold build.
5l plenum,
120mm "tapered" runners
Velocity stacks
Q45 TB
6mm alu sheetmetal

There is no flow simulation at all..Just all the bores are on centers..Tried get longest possible runners to get my peak torque as much to the left side. and 5l plenum and Q45 should gain some powah...thought I can gain powetr in 6-9k rpms and hopefully not kill any ponnies..
Remember few years back read mr Polks thread about best combo between volume/lentgh.. great details..

Enjoy

Very impressive, 30 psi by 4700 rpms for a turbo this size is just badass, you should be proud of yourself I noticed on the picture of your log the timing is only at 10 degrees, I think you can raise that up a bit, it might spool that turbo even faster and make the car a bit more responsive in the low end. PM me a log and I'll take a look at your timing settings and see if I can make some adjustments for you. If you have any questions never hesitate to ask, you have my attention and respect.

Thanks Man yeahh.. Iam proud and its great feeling its nice someone appreciate your work .. esp if you put lotta effort,hours of work after your day job.. / simple its about Do it yourself/Built not bought..

as for tune.. you are right.. did not tuned for spool up yet...I just using my bw s366 tune/timing..now just set my fueling to some safe area to tweak w VGT and see how turbo performs. secondly.. got el cut off exhaust ..going to install it. My target is get 15psi under 4k rpms
as for spool up tune.. found my car likes get richer afs during spool up.. and people usually going leaner...

Thanks!

 

[Boostdriven]

You do some impressive work my friend, I would love to drink a cold one with you

 

[MarsaGSX]

Thanks Man! thanks for your nice PM

well.. one day I will visit DSM shooutout so we can have a drink or two..


as for my build. Now I just removed my VGT fixer and put helper springs on VGT and set my Boost by gear to 100% during spool up..
first of I had spool 15psi at 4300rpms and 30psi at 5k rpms.. but then springs started stretched.. they were weak.. so my spool slows.. now Iam 15psi at 4700rpms and 30psi at 5600rpms..

have to find right spring.. right lenght and hardenes..


Venca

You do some impressive work my friend, I would love to drink a cold one with you

 

[MarsaGSX]

some updates guys.

Just fabed Exhaust back pressure sensor to log in link.
Omni4bar from ecmlink with 1meter long 6mm SS tube, and 20cm flex/vacuum line. Set on Baro input in link.

As for coolant sytsem..just switched to real "expansion tank" where coolant vented through expansion tank.This way if coolant temps starts become really high so the coolant starts to "burn" in head, there is possibility coolant becomes foam..and this foam aka air is then vented through exp tank.. Not like oem system..

 

[Boostdriven]

Setup is looking very nice man, keep up the good work and keep us posted on the progress with that monster VGT turbo

 

[MarsaGSX]

some update.. this time not happy...

was on the journey to my drag race event with hopes of looow 10sec slip..was funny trip.. lotta overtaking and was funn with my 2 friends.. 1G AWD Mid 12sec car and BNR 32GTR now low 12 sec car..

Lost my 4th gear during slow cruise.. when shifted from 4th to 5th.. was really weird.. when I shifted from 4th heard tooths.. was WTF was that.. and shifted to 5th.. but lost speed so shifted back 4th and.. was -.. where is my 4th.. felt just like neutral... so stoped car and after hour buddy came w trailer.. and found this..
BTW Pushing ONLY 33Psi boost w 16deg peak timing only..and using Jackstrans EVO3 gear cluster w welded center diff in my 2G AWD tranny case. Now ordered damaged stuff from Tim Zimmer and this time will fix it.. wanna try to cryotreat whole tranny.. to get some peace of mind.. but not sure what to do next time it happen.. wanna go AUTOAWD.. but not sure howmuch could take shipp whole AUTO drivetrain to Czech republic..

anyone selling ?? 2G auto awd for some low price and can arrange overseas cargo?? :

Thanks
Venca

 

[95DsManiac]

Very sick build. One word comes to mind when I look at your work man and that is inspirational. I've been wanting to do fab work and get into welding and after looking at your thread I think I'm going to just order the stuff to start practicing. I'm in the middle of my build right now and would love a top mount or forward facing manifold with v band exhaust. Good luck. I think 800 to the crank is going to be passed up once you actually get it on the dyno and get things dialed in. Like someone mentioned above, try a little more timing and see what happens. 10 degrees is quite low on e85. I wasn't pushing 30+ psi but with my 20g and e85 I was running 24+ up top and never knocked. I know I had more room but my engine blew before I can fine tune this last Wednesday.

Anyhow, good luck and have fun. Would be honored to meet you one day and talk cars . I know I can learn a lot just from a normal conversation with you. Can't wait for dyno videos and pictures.

Oh and your car looks very nice as well. I also have a red one. Love the color.

 

[Boostdriven]

Interesting how mayhem happens when you least expect it considering the damage I wonder if there are other gears that are not yet broken but weakened by the metal pieces going through them. If you haven't ordered the broken parts yet you might want to look in to getting a whole tranny. I picked up an EVO3 tranny with a transfer case some time ago on eBay for $600 dollars shipped to my door. It was one of them low mile trannys. There was nothing wrong with it when it was taken apart and I'm still using this tranny to this day. Hope you get your car running soon, I would like to see what kind of HP you get once you get it on the dyno. Good luck my friend.

 

[MarsaGSX]

Very sick build. One word comes to mind when I look at your work man and that is inspirational. I've been wanting to do fab work and get into welding and after looking at your thread I think I'm going to just order the stuff to start practicing. I'm in the middle of my build right now and would love a top mount or forward facing manifold with v band exhaust. Good luck. I think 800 to the crank is going to be passed up once you actually get it on the dyno and get things dialed in. Like someone mentioned above, try a little more timing and see what happens. 10 degrees is quite low on e85. I wasn't pushing 30+ psi but with my 20g and e85 I was running 24+ up top and never knocked. I know I had more room but my engine blew before I can fine tune this last Wednesday.

Anyhow, good luck and have fun. Would be honored to meet you one day and talk cars . I know I can learn a lot just from a normal conversation with you. Can't wait for dyno videos and pictures.

Oh and your car looks very nice as well. I also have a red one. Love the color.

Thanks Man
Just start your fab project.. then you know you need finish it
10deg timing at "peak torque" was first pull with VGT closed.. I just checking when she spools.. so i can dial timing and afs..
now iam running 17deg at peak rpms..w 33psi boost.. don´t wanna add another deg.. cus you don´t have real numbers from dyno if you gaining power.. read people was running high timings and then on dyno found it just hurts power, and lowered tmng.

one day come to DSM shootout would love to..trust me.. we can talk

Hopefully, once I bring her to life again..hope she can handle one full pass to get some ET and Trap.. and then going to dyno her to see how VGT performs.
Thanks again

Hi Alex

just answered your email ...been busy.. friend of mine had weddings.

we inspected my Evo3 gear cluster and found rest is okay..
so both 4th gears are gone.. ordered 4th gear plus intermediate shaft, and center diff is only thing which broke cus of those broken pieces from 4th.. and ordered some bearings too..

wanna get my trans cryoed..hopefully I can hit deadline for cryo..

Anyways would LOVE do auto awd swap.. cus if I broke her again.. not sure isf its resonable fix it again...

thanks for support!
Venca

Interesting how mayhem happens when you least expect it considering the damage I wonder if there are other gears that are not yet broken but weakened by the metal pieces going through them. If you haven't ordered the broken parts yet you might want to look in to getting a whole tranny. I picked up an EVO3 tranny with a transfer case some time ago on eBay for $600 dollars shipped to my door. It was one of them low mile trannys. There was nothing wrong with it when it was taken apart and I'm still using this tranny to this day. Hope you get your car running soon, I would like to see what kind of HP you get once you get it on the dyno. Good luck my friend.

 

[kaganader]

Just read your build, are there any more updates to this?
I love seeing people trying out VGT turbo setups and there results