drumbee23's turbo build

[drumbee23]

ok so i decided its about time to start my build thread in the turbo section, i wana keep my turbo build seperate from my member jurnal for certin reasons....

my plans for "phase 1" as some of you know are: DONE!!!!!


stock 2005 wrx tdo4 turbo-100$
i have a wrx intercooler(06)-60$
costum up pipe-50$
costum downpipe(2.5 in costum dp "blank", bungs, sti dp for flanges[possible high flowcat/reso])-60$
wastegate-a ko3 internal wastegate 3.8psi-40$
vortech FMU(12:1?)-80$
split second vc1-40$
oil feed and drain-40$
coolant hoses-30$
BOV-tubo xs-60$
home made heat shield-FREE, well bout an hrs worth of work


EM
vc1/vortech for now(not currently installed)
later on i plan to use the pro sequential piggy back, or somthing similar(greddy emanage?)



ok so my goals: 3/19/2009
about 220 CHP on stock motor(5psi)

"phase 2"
later on down the road(depends on money and time)(1-2yrs)
option 1: build a 251 with sti internals, oil pump, etc
option 2: buy a new sti short block

i would like to do the delta stg 2 head(turbo cams, nitrate valves(.5mm oversized) and PNP)
this would be on ether the built 251 or sti short block

with all that engine, i will prolly go with a vf39 or similar(just somthing larger then the stock wrx trubo)
and be putting out around 350chp or so (12-15psi maybe more,idk)

and at some point in ther i wil do my trans and such, but still undecided on that
aprx time for trans swap 6-12mths

5/20/2010-UPDATE!!!! ok so its finaly finish, well stage one is atleast. i got everything on bought some realy nice gauges. as of now im at bout 3-3.5 psi, any more and the cltuch will be gone! it pulls pretty nice. everything seems to be running good to even without the voltage clamp on. i do get a cel if i go past half throttle for more then a sec or two, but it goes away after i drive normal for alil. next i plan to get a new clutch some form of engine management. i also need new tires at this point in time and a few other little maintnece things that need to be done when i do the clutch. im having thoughts of doing the trans when the clutch gets done, just depends on $$$$

ok now some pics











ok so thats my plans and such now on with the build/many of questions

[drumbee23]

ok so this post will be about my turbo

its off an 05 wrx (tdo4)

coldside inlet-2 1/8"
coldside outlet-1 7/8


some pics from the guy i got it from, will post more when i get it

[drumbee23]

i plan to use the pro sequential piggy back...
here is a link to it site
http://www.moristech.com.au/pro-sequ...nterceptor.asp

PRO SEQUENTIAL INTERCEPTOR

The Moristech ‘Pro Sequential’ ECU is an ‘Interceptor’ type ECU that modifies the original Engine Management operation. It retains the factory idle, cruise control, dashboard, fuel closed loop control, knock sensing, traction control…etc.

The ‘Pro Sequential’ ECU stands apart from most other piggy back computers because fuel mixture is modified by intercepting the actual fuel injector pulse signal, not by modifying Airflow meter or MAP sensor signals. This method enables engines with larger size injectors, even low resistance injectors, to be tuned with ease. Fuel can be modified +/-100% and ignition timing up to +/-50 degrees totally independent of each other at any engine speed or load. An on board 22psi boost MAP sensor ensures correct tune even if the original engine sensors have been ‘saturated’ or reached their maximum reading. The unique design ensures a quick and easy tune with predictable and consistent results.
Tuning is performed in Real Time using Windows based software.

Advantages:

All existing features of the car will be retained
Interceptor can be easily removed, returning to original system.
Can control larger capacity HIGH or LOW resistance injectors (with low resistance injector driver option)
Built in turbo OVER BOOST fuel-cut eliminator
Ideal for applications such as low boost supercharging,/turbo charging and modifying naturally aspirated engines
Real-timing tuning. No uploading of entire tunes and waiting for programming.
Custom tune your engine - why be limited to a choice of pre-programmed tunes?
Easy and fast tuning - less dyno time needed
Tuning:

Ignition timing and fuel mixture changes are totally independent.
Tune Fuel Mapping to any required air/fuel ratio. Adjust fuel flow by –100% to +100%.
Alter Ignition Timing to any required value by advancing or retarding up to 50 degrees
Tune using Manifold Pressure (inbuilt +22PSI MAP or external GM 3 Bar) or Throttle Position
Powerful Engine DATALOGGER is a standard feature
EASY to use PC software allows all settings to be programmed in 'real-time'.
Each Fuel, Ignition and Stand-alone Map is constructed of 17 load points, every 500rpm, up to 10,000 rpm.
Helpful software tuning tools include:
Engine load and rpm history indicator
Quick key to jump to current engine load
Separate Fuel and Ignition trim
Warning indicator when fuel injector duty cycle is nearing 100%
Quick copy of load points to entire column or row
Datalogger:

Comprehensive display of real time and logged engine data parameters allowing analysis of:

Air/Fuel ratio
Fuel injector duty cycle and opening duration
Mass Airflow Meter and Manifold Absolute Pressure voltages
Engine tachometer
Throttle Position Sensor
Manifold pressure
Optional Extras:

Internal +22 PSI MAP Sensor
External 3 Bar GM MAP Sensor
Launch Control
3 auxiliary function outputs can be used for:
Nitrous (wet system) control
Nitrous (dry system) control with additional fuel mapping
RPM activated solenoid control
Gear change shift light
Intercooler spray
Extra fuel pump enable
Generic output if the above is not suitable
Built in electronic Boost Controller (solenoid required - factory solenoid can be used if equipped)
Supplementary Fueller :
Interceptor can be used as a powerfully featured supplementary injector controller.

The Moristech ‘Pro Sequential’ computer has up to 8 individual injector channels. Many vehicles and motorcycles can be tuned including Ford, Holden, BMW, Toyota, Mitsubishi, Subaru, Chrysler, Mazda, Suzuki , Honda, Kawasaki, Yamaha, and many others.

Plug in Patch Harness’s available for some applications.

If there is a new application not presently supported, a Moristech Interceptor can be designed to suit.

ok so thats everything from the one site i found on it....i think it will work good for what i need

[drumbee23]

probs with intercooler, first one dosent fit










and the space it goes in





it kinda fits:l cut down throttle body and IC alil but its too tight






specs on intercooler for my own use

Ypipe-2"
TB-2 3/4"

so after i got the 06 I/C i needed to make a pipe to connect it and it was one hell of a bend it needed to make....what i did was took a straight piece of 2 in pipe and cut it into angles and welded it together and here is what i got...sry for the blurry pics...

[drumbee23]

what im thinking for oil

supply-plug ontop of block near TB, took the plug, drilled a hole and tapped it with a 1/8 NPT. i then bought a 36in -4an ss line off ebay it came with a T to adapt in the oil pressure gauge. then i got the banjo fitting to go from M10x1.50 to a -4an line.









return- 5/8 line into pass side V-cover, welded a pice of pipe in



and coolant
supply-t'd into heater core lines 5/8"
return-t'd into heater core lines 5/8"

costomized coolant pipes

[drumbee23]

saved for up/dp info

finished product





up pipe (that birdpoop weld is not mine...i got the pipe like that, just havent gotten to fixing it yet)









downpipe "blank" (2.5")









test fitting pics












ok so i got the dp and cut the flange off







and just some more pics of lineing things up

[drumbee23]

i plan to use the wastegate that is on the turbo but can someone help me on figuring a way to lower the wastegate to 5psi cause if i remember right its set at like 8 or 10 or somthing....basically i need info on how to lower wastegate setting on a td04...

i would use an EWG but i was told for such a low psi it wasnt needed....is this true




oh and i geuss i didnt need to save that many posts...


ok i have been doing alot of reading on wastegates and MBC's and such and i came across a possible answer to my question

"The conection between the actuator rod and the wastegate is threaded. You have to unclip the actuator rod from the wastegate and turn the end of the rod. Shorter=more longer=less."

can anyone confirm this, it kinda makes sense....and they are sayin the stock wastegate is capable of going as low as ~5psi, wich is what i want....so if the wastegate is at the setting i want(5psi) do i need a boost controler....or can i just have a solid line running from turbo housing to wastegate....plz someone help me

that above is not entirely true....you can get it down to about 8psi...gonna go with a ko3 wastegate


so i got the ko3 yesterday...heres what it looks like normal







when im done with modding it will post those pics....i just need to drill some new holes..oh and recut the threads

[drumbee23]

just random pictures of it all








me dreaming it was that easy

[cloudconnects]

i care

i would also like to know about the wastegate, and boost controller. also whats your plan for a BOV?? i f you dont mind me asking how much did you pay for your turbo? its a td04 right? i think rexes come with td04

what are you doing for fuel?

[drumbee23]

yeh its hard to find things on that topic cause people never seem to cover that when they do a buil, i ended up finding that in a thread about MBC's...as far as a BOV, i need to listen to differnt ones do decided what i like....(anyone got a link to a vid with BOV sounds, and tells what BOV it is, thnx). as far as the td04 about 110$
as far as fuel, the pro sequential has the ability to increase fuel pressures, look here
http://www.moristech.com.au/pro-sequ...nterceptor.asp basically there is no need for a 5th injector like the other turbo kits out there...a new set of injectors would be nice but for 5psi i should be fine.....and this unit is alot differnt from the pp6, like the popping coil pack issue, this wolnt happen, the piggy back is my next thing to buy....yay 700$