233 replies to this topic

[soldave]

The replacement turbo has been ordered and will be getting put together from Tuesday or Wednesday. I'm going for the even more powerful 6-blade HX40 with a .84 a/r, twin-scroll T-4 housing. Round about equivalent to the 16cm Holset housing, it should give me at least 1.4bar by 3,900-4,000rpm. While my current setup will be run it it efficiently the 6-blade variant gives me space to grow in the future if I decide I wanna make even more power.

[soldave]

A few pics of what's going on inside the car. Going for something a little different with the mounting of the boost controller & power meter, so gave it to my buddy to do a little magic on. Here's what he's done so far (with more to come)

[Evo-00x]

I like the radiator sitting inside the radiator support panel, nice job.
Its great to write a list of things to do and cross them off as you go along. Psychologically, its a way of accomplishing one small achievement toward the finished product

[soldave]

Now this is what I'm talking about! My 2nd turbo is getting built as I type.

[soldave]

Turbo is completed and in the mail, Priority this time! HX40 with a Garrett .84 housing on the backside of it, T4 twin scroll and with a 3" v-band outlet. Fingers crossed in 10-14 days it might be here.





And my purchase of the day is a Billion VFC Pro fan controller. Would have preferred the fancy gauge one but this was cheaper and should do everything I want it to.

[CCEVO1]

Hx40 Look just like mine but bigger an better..😁

[soldave]

Turbo's in, yo! The latest one that was sent 6 days ago got from the far side of the States to Okinawa. Yeah, I'll probably go with the same quicker shipping next time rather than trying to save some cash and going with the cheaper option.

All hell breaks loose on Saturday as we only need a couple of other little accessories to get the car running. Lots to be fabricated but the centrepiece of the whole build is finally here.

[soldave]

Big props to my buddy Kris for making the interior look that little bit sexier. Out go the centre console vents and in comes boost controller and power meter.

[Cranked]

Looks factory almost.

[bazeng]

Nice!!

Fibreglass?
Any pics of the back?

[soldave]

Little fibreglass, little SEM texture coating, little black magic

[soldave]

And one more:

[soldave]

And finished off with a semi-gloss charcoal colour. Well worth the money and probably is the best looking thing in the whole interior!

[Qik-1.8]

i like

[bazeng]

Nice! I need to do my motec dash like that

[soldave]

Was a little more complex than straight gauges as I needed a backing plate on for the boost controller to sit on. Still came out real well though.

[soldave]

Rain sucks

Anyway, news of the day is: Man, mean4g is good at making stuff! I'm not too bad at tuning and car diagnostic stuff these days with the computers but he can build a mean motor. So the turbo is now on, with oil feed line (plus custom restrictor) in there. Downpipe is as sexual as they come. Am gonna have to heat wrap it but I want my fan to last over 10 minutes without melting so am going to have to! Clearances are about 1/4" either side so you can appreciate how close these things have had to be measured and fitted. The last of the downpipe is with the welders and getting made up now, as well as the drain line. Feed line banjo bolt they sent me didn't fit the turbo (think they'd send M12x1.25mm whereas the turbo inlet is M12x1.5mm) but we used a die on the banjo bolt so that's nice and snug too. And we're also pretty pleased with the intake. Blitz SUS filter gonna go on there once I have some more cash. So the top of the car is pretty much finished.

Exhaust valve to drill in, wiring to finish up when I have a clear night or three this week. and it could even start next weekend.

[bazeng]

I'd invest in a turbo beanie also. Maybe even wrap your manifold due to the length. I've Dennis 500 rpm spool up improvements with only heatwrapping on back to back dyno tests.

[soldave]

Already got a turbo blanket for it. Not installed yet as we just have to finish the oil drain line and then it'll all go on. Would wrap the exhaust manifold but it voids the warranty with JMF.

[soldave]

It's alive! Only just though, and what a mission it was to get it there. What I thought would be just an hour today ended up being 12 hours of constant work without any breaks on it. The battery got connected up relatively easily and without major incident, and that was where the simplicity ended.

When that was wired in I was able to connect the battery and see if everything did. My boost controller, fan controller and wideband did, but they stayed on when I pulled the key out! Realised I'd tapped into the wrong wire under the dash so had to redo that, and then a few other bits of wiring.

Got the oil line re-cut and welded and got that fitted up after much messing about. Problem is that the drain line comes dangerously close to the manifold. While it's not gonna be a big issue at idle or doddering around, I probably wouldn't want to do any full power runs in it when exhaust temps inside the exhaust manifold are 1600F or so. The flanges are aluminium too which have melting points of 1200F. They should be ok but I might need to extend one of the lines so I've very little rubber line close to the manifold.

Got that fitted up though and the car filled with oil. Did the same with coolant, after dealing with a coolant leak and realising the radiator is sealed with no drain (my bad... forgot to request that!). And then it came time to test it again. I wanted to test the fuelling to make sure there weren't any leaks after changing to the new FPR. Activated the fuel pump and the pressure gauge went up to 46psi monentarily, and then dropped to 10psi and stayed there. Strange. Tried again and only 10psi again. Checked voltage to the pump which was fine and the pump was definitely working. Changed back to stock fuel pressure regulator and no change. Tried firing up the car and it would sometimes try to cough or start for a split second but would then die again. After an hour or so I pulled the Walbro out as I'd assumed it was bad. Had a look and it turns out when I put in the Walbro in I hadn't transferred over the plastic spacer that goes in before the o-ring on top of the pump itself. We replaced the stock Evo III one with a much better Evo VIII 3-level o-ring and put it all back in.

Tested the fuel pump again and had fuel spurting all over from a couple of leaks near the FPR. Took a while and new hose but sorted those out too. And then I turned the key finally and it started up.

For the first time in almost 4 months it was idling. It has thrown up a CEL which I need to work on diagnosing, but will look at that tomorrow after work. I think it's something to do with the speed density setup I'm trying to get working. We also have an exhaust leak at the turbo-downpipe v-band, and we broke an older v-band clamp further down in the exhaust, but those can be sorted out quickly enough.

So a hell of a long day, but finally a bit of progress

Edited by soldave, 29 January 2012 - 03:37 PM.