My Turbo Buildup

[totaleclipse_05]

UPDATE GUYS:

Mounted the FMIC today. Was kind of a pain to do, ran to the hardware store about 3-4 times to get everything i needed. Turned out pretty good though actually, I'm happy with it. Here are some pics:

Ghetto/ Custom Brackets:

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Mounted on car:

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With bumper on (had to hack a bunch off)

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I have a bunch more pics so if anyone needs help or doesn't get how I did something, just post and I'll try to explain.

 

[DSMcrazy3]

Great job Mike..Now go mount mine

 

[BigRand]

So pretty

 

[VelocitàPaola]

Did you keep the bumper support, or no? I noticed your bumper cover is sagging a very little bit on the passenger's side... as is mine. I'm wondering if finding a way to mount the bumper support (a little harder for me, because I have the Hahn FMIC, so my outlet port is right there) will help.

 

[totaleclipse_05]

Did you keep the bumper support, or no? I noticed your bumper cover is sagging a very little bit on the passenger's side... as is mine. I'm wondering if finding a way to mount the bumper support (a little harder for me, because I have the Hahn FMIC, so my outlet port is right there) will help.

Nah, I would have zero room for this intercooler if I had kept it on. The reason it sags a bit is because there is 1 hole on each side not being used in between the 2 on the fender and the 5 in the middle. If I can find a way to utilize those 2 extra ones, the sagging should go away. I'm not too picky though and it seems fine for me so I'm not gonna worry about it.

 

[totaleclipse_05]

A little update,

Worked on my car from about 4 pm yesterday until 3:30 in the morning. Have the manifold and turbo mounted up, downpipe is basically on, and intercooler piping is just about done (1 pipe left). I just need to finish oil lines, the 1 pipe, FCD, and various little things (tightening things, ziptie stuff ha). So far so good IMO, we had some things that gave us a rough time, but I believe the hardest is over and its gonna go downhill from here. We didn't make our Sep. 2006 deadline, but it was close . I need a nap before I work on the car some more, 3 hours of sleep and then went into work for 8 hours. I'm a little tuckered out haha. Pics will be posted ASAP so don't worry guys. Thanks for keeping up with my project.

Thanks to Josh for all his help so far, couldn't have gone this far in this amount of time without ya.

 

[DSMcrazy3]

The boost hath arrived! There's a leak somewhere, whether exhaust(pre-turbo) or boost causing a slow spool time, but we'll get on that tomorrow.



Pics coming soon!

 

[totaleclipse_05]

Alright guys, sorry about the long wait. I have been working this whole week and along with school, I had no time to fiddle around with the car, nor post pics.

The boost leak Josh was talking about has been fixed as of tonight and spools very fast now. There was a oil leak on the return fitting of the oil pan and on the return flange of the turbo that didn't turn up until a day or so later. Finally got around to messing with it and now it doesn't leak around the oil pan fitting, but under boost, the turbo return flange leaks a bit. Not as much as it was before, but still does. I have one problem that kind of leaves me stooped though, but I have an idea what it could be. Just want some more opinions on it. I have checked the vacuum line and it is fine also.

My car was leaning out at WOT, not at 3/4ths or anything, just WOT. I was reading up that a tear in the gasket on the FMU would maybe cause this and I do have a pretty big scrape on mine that goes across the gasket area. Do you think this could cause it not providing enough fuel? I was going to pull it off now and take off all the allen heads screws and maybe fill that area (or the whole area) with some gasket maker and let it sit and cure. I hope that could be the solution. Just wanted some insight on what you guys have to say. I also think I need to mess around with my FCD too, but was going to do the FMU first.

Also the internal wastegate probably wants to boost too high, but I don't get that far to see what it's set at. It's ok though, I'm getting an external wastegate in on tuesday which will probably go on right away. It's set for 6 psi so I should be ok with that. I'll post some pics up in just a few minutes.

 

[totaleclipse_05]

OK, here are some pics:

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OLD OLD Engine Shot:

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Before Turbo:

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Current Engine Shot:

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Thanks to everyone who has been checking out and keeping up with this thread. It is an awesome feeling knowing that I did all that. I will keep you guy's up to date with car until it is running good haha.

 

[totaleclipse_05]

OK, took off the FCD on my car and it stops the leaning out problem. FCD is not working good so I am in need of another. Oil leak is from the return flange on the turbo, another one should come in next week. Pulls great though, its around 5 psi or so on an internal wastegate. External wastegate comes in on tuesday so I guess there car will have to come apart again that day.

 

[TalonESIT]

Be careful with that radiator hose, make sure you find something to protect it from all of that heat! Nice job on the install ^.^



Also, how are you hooking up the ext. wastegate? do you have another header flanged for one?

 

[totaleclipse_05]

Plan on welding a flange for the external wastegate on the manifold I'm using now. Pretty sure it will work and hold up good. I'm sure down the road I will get a new manifold flanged for an external wastegate already though.

With the new downpipe I'm going to use, It should stay farther away from the radiator hose. I'll probably still wrap something around it like you recommended Terry.

 

[DSMcrazy3]

Be careful with that radiator hose, make sure you find something to protect it from all of that heat!

That's the same exact set-up I had(I gave it to him) I had nothing around my radiator hose for over a year and it was fine.

 

[totaleclipse_05]

I think actually in that pic it makes it look right next to the hose. There is actually about a 1 in. gap between the two.

 

[VelocitàPaola]

OK, took off the FCD on my car and it stops the leaning out problem. FCD is not working good so I am in need of another.

Ah ha! I knew that guy's FCDs are crap! I got you covered, though, hit me up with a PM.

 

[VelocitàPaola]

...like you recommended Terry.

Psst. That's not Terry, that's Errol. Terry is Talon ESI-T. Errol is TalonESIT.

 

[totaleclipse_05]

AH my bad man. Thanks for clearing that up. I just took a quick glance at the name before typing it. Sorry.

 

[Randomrage]

Man, good job, and welcome to the Boost Club. Now we shall teach you the secret handshake and you may partake in our insanely hot orgy fests!

Ok, just kidding on that last part. XD

Yo, Paola, I think my Missing Link is causing my hesitation at 4000rpm, I need one of your FCD's also.

 

[BigRand]

So Paul, when you gonna start mass producing these FCD...just set up a little myspace account or website for em, and a paypal link..., good luck with the quality products.

 

[TalonESIT]

Psst. That's not Terry, that's Errol. Terry is Talon ESI-T. Errol is TalonESIT.

Lol, yeah it just so happens that our handles are so close... but don't confuse that with our knowledge! I have nothing on Terry! !

 

[VelocitàPaola]

Haha, it's funny you ask... I was just getting ready to make a bunch of dataloggers, FCDs and SPC boxes... but, uh, I'll keep it to PMs from here...

 

[Talon ESI-T]

That FCD must be assembled wrong. They work quite well, I should know i have made a few and use one myself. Paul just liek to over engineer things..

I would try to get the fire sleeve that Hahn sells in his kit. I have always run mine without any kind of wrap and yes it is fine but I did have a lot of heatsoak till i went to a Fluidyne. Now The heatsoak was through the radiator as well as the hose, so i am not going in that direction. I am not telling you heatsoak is the issue but rather the rubber of the hose against the heat. We all know how heat destroys rubber and we all want a reliable project. A fire sleeve is a small insurance policy that will preserve the longevity of the radiator hose and prevent a blown hose while on the road. Just a small piece of mind.

My O2 wiring used to be routed in the factory location when i first installed my Star kit and yes the heat melted right through the wire loom in the course of a summer. I dont want to put anything through that kind of stress if i plan to rely on the car to start and run well everytime i push it.

You have to think reliable if you want to enjoy this. Not teling you to sink a ton of cash but to take the extra measure to do a quality job when you build your car.

Terry

 

[XMasta19]

...car has to stop breaking before I can enjoy it

 

[InfiniteGSX]

could you show photos of the oil feed setup... closeups on the turbo and where the feed line starts, the fittings used... I'm about to start one of my BudJET projects and this is all I need left. I have the IC, Pipeing, Turbo, Wastegate, BOV... shit everything except the manifold (still haven't ordered) and the downpipe (because I dont have the manifold to bolt the turbo) and I am going to need this stuff soon.

 

[VelocitàPaola]

could you show photos of the oil feed setup... closeups on the turbo and where the feed line starts, the fittings used...

Will these help?