My compound turbo set-up

[99gst_racer]

I figured it's about time I share this project with everyone on this site. I've been tinkering with this since November of '08 and it's finally almost complete.

Cliff notes on function: Two turbos are used, one smaller than the other. The smaller turbo get exhaust first in the stream, and the smaller compressor receives compressed air from the larger turbo's compressor. Being that pressure ratios multiple, this type of set-up can yield a large amount of dense air very quickly. Translation = lots of boost and very quick spool. Another huge advantage to this type of set-up is that it's capable of running more boost than any single turbo. This is how tractor pulling guys achieve 200 psi boost.

For a more detailed explanation of it's function, read this article: Diesel Power Source - Articles - Turbos/Twin Turbos - Twin Turbos vs. Single Turbo

And for you visual people out there, here is a picture of a compound set-up on a Cummins diesel engine:

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These are pictures of the final product. Pics early 2010:

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Never be afraid to try something new. Remember, amateurs built the ark. Professionals built the Titanic.

 

[99gst_racer]

Initial mock-up pictures. This shows the only spot I can fit a second turbo on my 2G.

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Getting started on fabbing the crosspipe to connect the two turbine housings:

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All tacked up:

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[toofast82]

Can't wait to see it done!
Any thoughts on selling a kit or anything?

 

[99gst_racer]

TIG'd and braced:

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[99gst_racer]

Can't wait to see it done!
Any thoughts on selling a kit or anything?

No, I definitely don't have the patience to build another one anytime soon. There's no telling if this entire set-up will be for sale sometime in the future though. Depoends on how the rest of my car likes it.



More pictures in a hour. I have to run to the body shop right now.

 

[Artago]

MORE!!!!!..


Subscribed....


Looks sick... can't wait to see the finished product.

Tom

 

[toofast82]

No, I definitely don't have the patience to build another one anytime soon. There's no telling if this entire set-up will be for sale sometime in the future though. Depoends on how the rest of my car likes it.

Very understandable, how much time do you think you have invested in it so far?
I posted before your last pics, but the setup looks simply badass

 

[TRSblader]

Interested to see how the finished product turns out, how the car reacts, and what type of numbers it makes. Looking great so far

 

[habitatguy187]

I was looking through your profile pictures the other day and saw this, awesome work. How fast does it spool?

 

[toofast82]

How fast does it spool?

Doesn't sound like like he's road tested it yet.
He's almost done, be patient, i'm pretty excited to see it going myself

 

[untouchablecc]

That is amazing i have seen that done on the 09 evo 4g63 engine but never on a dsm, i wonder how fast it will spool.

 

[andy4g63]

You are my hero, Paul. Just DO NOT BLOW the bithch from very first time. Try and set it up correctly. Even AMS gave up on their compound twin turbo set-up at Castrol Challenge, so I know it ain't f###ing easy. Good luck, man...

 

[99gst_racer]

Wastegate inlet time:

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[Redwidow]

Very nice work, and nice choice of beer!

 

[GS-T_Newboost]

Very nice work, and nice choice of beer!

Yea indeed. I was also peepin your profile pics the other day and seen this. You bout ready to hit the key or what?

 

[andy4g63]

Very nice work, and nice choice of beer!

Without PLENTY of beer, you CAN NOT get any job done...

 

[Redwidow]

Without PLENTY of beer, you CAN NOT get any job done...

well I dont know about you but when trying to accomplish something, a few beers while working is great but after 3 or 4 they start going down like aquafina and I become very unmotivated to work on the car and very motivated to finish the case .
-Andy

 

[brainlessher0]

Reminds me of our twin turbo srt-4 except 100000 X cooler

 

[99gst_racer]

Machining the manifold for the wastegate port:

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[GS-T_Newboost]

Reminds me of our twin turbo srt-4 except 100000 X cooler

I couldnt imagine tryin to get a twin turbo srt-4 to hook. Its hard enough with one turbo let alone two. I got a feeling this setup will have a little traction issues even with awd.

 

[zckry]

Yikes! Have fun tuning that

 

[ApexVIII]

That is amazing i have seen that done on the 09 evo 4g63 engine but never on a dsm, i wonder how fast it will spool.

hrm, i do not believe this has been done yet, as there is no Evo X's with 4G63's

the Evo X's have 4B11t's

but nice work on the cutom set up to the OP!!! very sick!

 

[99gst_racer]

Port matched the manifold:

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Welded the inlet tube on:

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[bluegs03]

now theres something different! Good luck with it, im still trying to wrap my head around the dynamics of how thats going to work but i think i understand! ok after thinking it thru i have a few questions. I understand the concept the smaller turbo spools up fast and is boosting then the larger turbo kicks a larger amount of boost at the engine when it finally spools.

My question is this, looking at the example from the diesel twin design, when the small turbo is spooled and say boosting 10psi, then the big turbo kicks in and kicks 30 psi straight into the smaller turbo, which would then go into the intercooler piping and eventually into the intake manifold.

How can the smaller turbo make use of the boost? Basically you got this tiny turbo which has an small efficiency range and is good for small boost, which is great until the extra 30 psi comes and crams it way into the small turbo, wouldnt any gain be lost from the larger turbo by trying to cram 40 psi into a turbo thats only meant for 10-20 psi aka 14b? it would be way out of its efficency range and the exhaust turbine housing wouldnt be able to flow that much right? Even if the 40 psi somehow made it threw the small turbo wouldnt this cause the small turbo to literally self destruct? Let me know if i need to rephrase the question for clarity.

 

[DSM_PWR]

I couldnt imagine tryin to get a twin turbo srt-4 to hook. Its hard enough with one turbo let alone two. I got a feeling this setup will have a little traction issues even with awd.

ACTUALLY... no..

It should actually help with traction issues.. think about it, a bigger turbo will lag then hit hard once boost comes into play... that hard hit is what breaks traction and makes you spin..

Now think about it, if you've got a smaller turbo that kicks in at a much lower RPM, then once the bigger turbo finally hits, you wont feel the kick because you'll already be boosting from the smaller turbo..

How do i know? Ive been hanging around Boostlogic the last couple of months while they tested their new Compound Turbo setup and let me tell you... its VERY IMPRESSIVE!!

Not only have they reached some pretty sick numbers! but the spoolup is amazing... no more need for nitrous

Marc @ Boostlogic has a compound setup on his 2JZ 300zx and he took me for a ride, man that thing has little to no traction issues even with crappy tires and he's pushing 700whp on e85 on a 2600lb car