Mawnee's Custom Turbo build
07-04-2009, 01:46 PM
#101
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I wasnt happy with the manifold. The turbo sat a little farther forward than I wanted and was twisted in relation to the engine. It was making lining up the intake pipes and cutting a downpipe difficult. So last night I cut one of the welds and repositioned it then welded everything up. Spent time leak testing the manifold and welding a couple pinholes. Manifold is totally finished now and my turbo is positioned perfect!
Unfortunately after I finished it and was cleaning up the garage I heard a gas leak in my welder. Found the gas line that goes up through my wire to the gun had a leak. Lost a third of my tank of gas to it too
Now I'm off to home depot to track down some tubing to fix it.
Hoping to get my Downpipe done tonight then button things up tomorrow.
Unfortunately after I finished it and was cleaning up the garage I heard a gas leak in my welder. Found the gas line that goes up through my wire to the gun had a leak. Lost a third of my tank of gas to it too
Now I'm off to home depot to track down some tubing to fix it. Hoping to get my Downpipe done tonight then button things up tomorrow.
07-05-2009, 06:46 AM
#102
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Unfortunately noone carries 3/16" nylon tubing I need to fix my welder around here. Smallest I could find was 1/4". I ordered some online, but no way am I going to wait for it. I patched up the leaking line by slipping some 1/8" tubing over the spilt with some goop in to seal it up. It may be leaking a little, but my tank pressure is holding and I can weld!
So I got my downpipe cut and tacked together. Its a bitch to get wrestled down into the engine bay. I actually have to have the motor mount hanging loose to get it through. That top motor mount bolt is gonna be a pain to get on but should be doable. Now I gotta get my wastegate tube made and welded on the downpipe along with the two 02 sensor bungs.
So I got my downpipe cut and tacked together. Its a bitch to get wrestled down into the engine bay. I actually have to have the motor mount hanging loose to get it through. That top motor mount bolt is gonna be a pain to get on but should be doable. Now I gotta get my wastegate tube made and welded on the downpipe along with the two 02 sensor bungs.
07-05-2009, 08:39 AM
#104
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07-06-2009, 01:19 AM
#105
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My welder failed again and screwed up my day. This time i couldnt patch it. It will have to wait till my new line comes in. Fortunately I have a friend with access to a good welder and ran over there to finish my downpipe and weld together a downturn with a flange I can clamp it to my downpipe and run the car sans exhaust 
I'll weld up my exhaust system once my gas line comes in for the welder.
Now I just need to get my Downpipe wrapped and installed. Mount my intercooler. Then cut my intercooler/intake pipes and get everything hooked up.
Almost there.....
I'll weld up my exhaust system once my gas line comes in for the welder.Now I just need to get my Downpipe wrapped and installed. Mount my intercooler. Then cut my intercooler/intake pipes and get everything hooked up.
Almost there.....
07-06-2009, 09:05 PM
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07-07-2009, 01:56 AM
#108
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I have gotten nowhere. Turns out the way the turbo is clocked on my manifold that the oil drain fitting wont fit on it. The actual hot side housing inlet flange blocks the huge *** AN fittings that need to go on it. I've taken those fittings aprt and put them back together so many times they are probably going to leak.... 
Last edited by Mawnee; 07-07-2009 at 05:18 AM.
07-08-2009, 04:51 AM
#112
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Thanks
Later Today:
-Need to run out and buy a few hose clamps to button up the coolant lines.
-Then cut a few intercooler pipes and get that all together.
-hook up my wideband and tru-boost to a power source.
-add fluids
-flash to my base tune
-Start the car!
Later Today:
-Need to run out and buy a few hose clamps to button up the coolant lines.
-Then cut a few intercooler pipes and get that all together.
-hook up my wideband and tru-boost to a power source.
-add fluids
-flash to my base tune
-Start the car!
07-08-2009, 05:28 AM
#114
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Still have to open up the hole into the bumper a bit so I can straighten out those pipes better.
Also going to have the MAF a bit farther forward and add some striaght pipe behind it as well.
I bought 3' of that 3.5" tubing so I can play around with it.
07-08-2009, 11:59 AM
#116
the maf location seems fine to me, but you going to run into a problem if you don't recirculate the the bov back between the turbo inlet and the maf.
if you don't the bov will actually suck in air at idle or crusing speeds, this will be un-metered air and the car will run really rough. as its getting more air then it thinks
if you recirculate the bov between the maf and turbo, then you will be fine because it will suck in metered air.
I hope this makes sense
if you don't the bov will actually suck in air at idle or crusing speeds, this will be un-metered air and the car will run really rough. as its getting more air then it thinks
if you recirculate the bov between the maf and turbo, then you will be fine because it will suck in metered air.
I hope this makes sense
07-08-2009, 12:05 PM
#117
Yes; it will be problematic if you don't recirculate - but you can tune it to stay closed at idle and part throttle - you may just get stalling. When BOV's open as a rule they let air out; and the car runs rich.
The only BOV that reliably opens in all engine vacuum is the Syncronic; and it was designed to do so.
The only BOV that reliably opens in all engine vacuum is the Syncronic; and it was designed to do so.
07-08-2009, 02:36 PM
#118
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Going to try to run without recirc. As sensitive as the Maf is to any turbulence and as little room as I have to get straight smooth pipe in there I'm afraid I wont be able to do so without screwing up the Maf readings .
My intent is to eventually get the synchronic BOV to match my wastegate.
Last edited by Mawnee; 07-08-2009 at 02:48 PM.
07-08-2009, 05:49 PM
#120
Yes; it will be problematic if you don't recirculate - but you can tune it to stay closed at idle and part throttle - you may just get stalling. When BOV's open as a rule they let air out; and the car runs rich.
The only BOV that reliably opens in all engine vacuum is the Syncronic; and it was designed to do so.
The only BOV that reliably opens in all engine vacuum is the Syncronic; and it was designed to do so.
07-09-2009, 08:44 AM
#124
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Ran into some issues, will try to start it tonight after work.
I"m going to have to completely redo my intercooler pipes though. Intercooler sits too far forward and the bumper wont fit back on.
I"m going to have to completely redo my intercooler pipes though. Intercooler sits too far forward and the bumper wont fit back on.
07-09-2009, 10:56 AM
#125
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I love watching this build and commend u on the ***** to DIY. I would love to do something similar, but I just don't have the funds. Would really like that t70 turbo kit out there but where do I get 6 grand from.... Where do you guys find the extra money to do all this stuff? My car payment/ins is $500/mo. Rent and bills $800/mo. I bring home about $2200/mo but for some reason everything is so damn expensive. Food, gas, beer beer beer.... And the wife. Guess I'm jealous LOL.