Ok, so I've made the plunge to go turbo on my 03 Screaming Yellow SVT. The cars got 73k on the clock, and I bought it with 18k. Anyway it's been stock except for eibach sport kit and a cold air....up until now. So here are the plans:

So far I've installed the intercooler and fabbed the manifold. I'll post some pics later today of whats done so far.

Custom log manifold, 304L SS built by me.
SCT X3 with Pro Racer Package
2 gauge piller pod, boost and 02 (I know it's just a light show)
Ebay special items-
Turbo - T3/T4 T04E
Intercooler- 28x7x2.5 w/ Greddy Type-R blowoff part of the deal
38mm Wastegate- Tial look-a-like with 8psi spring
T3 flanges in stainless
Brand new precision 42# injectors of ebay, I know should've gone with 60's but these kept me in my budget.

My idea is to be able to keep the car on the road while making the transformation, hence mounting the intercooler already. I've started mounting the gauge pod with the gauges but ran out of light yesterday after work. This weekend I want to mock up the manifold to the head and make sure my design will work. Also while I'm there, I'll fit up the down pipe and the cold piping. I plan on using part of my cold air piping as my charge piping from the intercooler outlet although I think it may be a bit too big causing a big drop in pressure but I have to try. Thats pretty much it for now, I'll get some pics up and keep everyone posted if there's interest.

I'm open to suggestions as well.

Thanks,
John

how much is your "budget"

pictures por favor

lol. and friend of mine is running an ebay 16g on his ecplise and its been running fine.

Well I have a tight budget of 1400. Currently I'm over by 30 bucks but I think I'm complete as far as purchasing, that's down to the t-bolt clamps! That said I'm attaching a few pics. The manifold is made from scratch excluding the turbo flange, also a ebay item! The last two pictures show the intercooler as it sits in the car, my camera died otherwise I would've shown the install of the intercooler. I'll try to post the whole tranformation as I go. I can post some pics of the turbo and such if interested.

Enjoy.....

i have a complete kit and sofar i spent $1000 including gauges and fittings and everything. all i have to do is put it on and get it tuned.

1000. is pretty good but keep in mind that 1480. includes the purchase of the SCT X3 and the PRP. That alone was around 750. So I don't think I did all that bad cost wise.

wow that is cheap any links to the seller you bought the turbo from

you better buy a real turbo there are alot of honda guys with ebay turboes that went out the 4th day they put it on why dont you jus use the money to buy a real turbo

I agree, also i would go for a T3 super 60 series instead of the t3/t4

Well I agree that those turbos on ebay are cheap for a reason, but without first hand experience I can not make a statement like that Roushturboedzx3. This build isn't my first, I've built 8-9 turbo creations, none with a ebay china made turbos though. One of my builds was a starquest (89 Mitsu. Starion or Conquest) which made well over 400hp using a 20G stage 2 turbo. That turbo at the time cost me almost a 1000. So believe me I know what you mean and I've seen the good and the bad.

I'm not expecting much from this other than a little bump in performance to bring my SVT to 225-250hp as a daily driver on 8-10psi of boost. I'm not looking to break SVT HP records or anything like that but like most of us in these forums, we would like a little more for less... otherwise our project cars would be more in the relm of a WRC RS or some sort of exotic supercar! Please don't jump down my back because of that statement, I admire all types of cars and they don't have to cost 200grand.

One of my last builds was my brothers 91 stang twin turbo...with ebay turbos. Although they are real deal garrett's they perform amazing. His car mildly tuned by me using a AEM plug and play ECU on 8.5 pounds of boost has put down 430+HP and something like 455Tq.

So we'll see. Hey badass3 I just searched and searched between all the deals to find the best one's.

BTW I planned on making a sister kit for anyone interested minus the SCT stuff that I might sell. Also anyone in the LI NY area is welcome to get together with me to see the build.

Thanks,
John

how much for the sister kit?

Not really sure yet, but I'll keep you posted as I go.

-John

see this is where i dont see why everyone expects to pay out the butt for a home made turbo kit. i also added the figures up and barely went over 1500$

wordyahurdd, you pay for fabrication time. My manifold alone has 8-10 hrs of labor from start to finish. And it's the simplest in design being a log. But at the same token, I don't believe in paying 5-6k for a kit to be ok, I don't care how much power it made on the last car it went on, That's just me though.

-John

wordyahurdd, you pay for fabrication time. My manifold alone has 8-10 hrs of labor from start to finish. And it's the simplest in design being a log. But at the same token, I don't believe in paying 5-6k for a kit to be ok, I don't care how much power it made on the last car it went on, That's just me though.

-John

I am also doing the custom turbo thing (http://www.focusfanatics.com/forum/showthread.php?p=2344436#post2344436) and with a T3 Super 60, Focus Power manifold/downpipe with AEM wideband, Autometer boost/egt gauges, intercooler and piping, -10AN drain hose and braided feed line, Greddy BOV and Evo wastegate, I'm well over 2700 let alone talking tuning and J&S. So to each saying that it can be done on 1400, it may well be, but nothing proven and well built.

I don't want to make this a pissing match but what do you mean by well built. Are you saying there might be something wrong with what I've built so far? the header?[dunno] Also are you doing all the work?

High cost doesn't mean well built in my book.[dunno]

exactly!

No, I'm not questioning the craftsmanship of your welds, or your manifold. I really question the durability, or the overall quality of knock off wastegates, bovs, and turbos. The intercooler should be fine, although some will debate, but i've seen other makes and models of cars use ebay brands such as CXRacing and Mishimoto intercoolers effectively.

I guess my biggest concern is the fact that the SVT is, and always will be a difficult car to safely strap boost to. Its going to be hard to tune your setup without a wideband O2 controller, as thats not something that the SCT PRP can accomplish. Furthermore, an aftermarket knock indication gauge is required, as knock on a relatively high compressioned motor such as ours can be difficult is not impossible to manage. And thats without saying that the stock SVT knock sensor will add timing when it sees knock, which isn't beneficial, nor safe at all. Just in a wideband ($240 on the low end) and a J&S ($700 with gauge from CFM), and roughly 4 hours of dyno time for the tune ($600 at McNews, I'd imagine thats a good baseline number) your well over $1500 in electronics, to safely ingest mass quantities of compressed air into that huffing puffing SVT motor.

To even add at that number, you will want to look into a blowthrough setup for a more driveabilty factor, which, even at your power level is a safe bet of a 3" MAF tube ($100) and a MAFia to keep MAF voltage down ($175). With all that being said, even at 250-260ish horsepower, the stock SVT clutch, as we all know isn't exactly a reliable setup, even in stock form, and at 260ish HP, you are going to start to deteriorate clutch life, of which even the cheapest of the after market SVT clutches rain in at $750, due to changing the flywheel to adapt to an aftermarket clutch.

With all this said, I know from experience that turbocharging an SVT focus is no easy, or cheap by any means task. And you should really look into your safety, tune, and reliability factors first, before your undergo this project. I'm sure most members on here can attest to the fact that engine builds are not cheap, and its safe to keep a setup such as this street able, and reliable at the same time. I hope my post cleared up my opinion.

AerofurySC...I agree with your reasoning, ideas, and method but at the same time I'm not sure you see my point. I don't think throwing parts at a car is what signafies a good "kit" or a good build. I also am NOT building a daily driven RACE CAR.....
I've done alot of research regarding this subject and I'll proceed as planned. I would think as a fellow SVT fan you would speak words of concern but at the same time encourage the build. I'm not one to dog someone for trying. I also believe that we all understand the risks envolved in any performance inhancements....right? That's why I've owned my car for 4 yrs with only a cold air!
Anyway I typically don't post anything on my builds for this very reason, this time I thought there would be interest in it.......I guess not.[dunno]

BTW, you never answered my question, are you doing all the work on your car yourself?

-John

Yes, everything done to my car thus far I've all done myself (Gates timing belt, TB, full exhaust, CAI, etc, etc.) and the turbo setup I'll be installing this winter, as I park my car in the garage while the salt is out.

Aero I wish you luck with the build...
I'll keep you guys posted.

-John

I think we are all interested in your build....

What are you going to do about an aftermarket knock sensor. From experience....and trust me on this, the last thing you want is for the stock sensor to add timing!

Well that's a very good question... My understanding is that the purpose of any knock sensor is to PULL Timing not add timing. By no means am I trying to say your wrong. Why would the SVT want to add timing when it senses a knock
A quick look at the Knock sensor function in the Pro Racer Package software shows timing being pulled not added. Also this statement is made in the software under that function, " The value is the amount of spark retard, so it's assumed that it's retarded, so it does not need to be negative." [scratch]
All the values are positive.

I'm going to look into this further, if someone else wants to chime in....

-John

The SVT knock sensor is nutorious for adding timing and blowing engines

Is that because of a bad knock sensor? or just the way ford designed the ECU.

-John

I do not know the reason behind it but that is what the knock sensor for the SVT does. It added 9° to mine at 6k rpms and thats when my motor went.

03OrangeSVT can probably explain it a little more

03OrangeSVT do you have any input on this?

Thanks

-John

Yep, The way the knocksensor is set up from Ford it can add timing as well as pull timing and it has been known to blow more than one engine.

You can turn off the "add timing" function with the software..... BUT there is NO way to log the knock sensor so you do not know where or when timing is being pulled.

Thats where the J&S Ultrasafeguard comes in.... its a stand alone KS system that utilizes the stock sensor and comes with a visual (gauge) indicator of when knock is occuring... AND its adjustable.

IMO its needed for ANY SVT that has boost.

Yep, The way the knocksensor is set up from Ford it can add timing as well as pull timing and it has been known to blow more than one engine.

You can turn off the "add timing" function with the software..... BUT there is NO way to log the knock sensor so you do not know where or when timing is being pulled.

Thats where the J&S Ultrasafeguard comes in.... its a stand alone KS system that utilizes the stock sensor and comes with a visual (gauge) indicator of when knock is occuring... AND its adjustable.

IMO its needed for ANY SVT that has boost.

YOu know I think if I were you I would add this little snippet of info to your sticky thread about going FI.....Thats a very important thing for people to be aware of.

The J&S is a must, and once you have it and use it. You will wonder how you ever thought about not having it. Which is cheaper? J&S or a new motor? Protect your build and get the J&S.

The manifold looks very good, good luck with the build.
Ive been wondering if you could use a normal zetec computer on the SVT. You could get a processor and a knock sensor for cheap, the only thing I dont think you can control would be the VCT, which is easy to delete. There is a IMRC function in the Zetec computer, so you could still control your intake mani. This would do away with needing the J&S.
The Knock Sensor in non-SVT zetecs is supposed to be pretty good. I

I dont think that will work because of the PATS system. You would need new keys and a re-flash.

After all that you could have just bought a J&S.

I forgot about the PATS. I know theres a way around it, but your right thats a LOT of extra work.
Is J&S the only device that will work?

You don't need new keys just need them reprogrammed to the new ecu. It's fairly cheap and takes ten mins and either way you will need re-flashed cause with the boost you'll need tuned anyway

i had to run a j&S with my set up as well and i have a zetec. mine wasnt adding timing, it was removing to much. so even if you did it get it reprogrammed work you take the chance of it not working.

btw any one have a LUY4 ecu they dont need? mine doesnt work any more [poke]

You don't need new keys just need them reprogrammed to the new ecu. It's fairly cheap and takes ten mins and either way you will need re-flashed cause with the boost you'll need tuned anyway

To tune you dont need a re-flash.

Thanks for all the info and help so far. I got alot done this past weekend. I bolted up the manifold things fit pretty good. I wasn't 100% happy with the placement of the turbo so I ended up moving the turbo 1" towards the passenger side. All in all things fit very nicely. The spacing between the fans seems pretty good as well, it's actually about 1" plus. I plan on wrapping the turbo so I think that's plenty. Ok so here's what got done:

Header Complete
Wastegate mocked and piped... 98% complete (Need to finish some welding)
Downpipe Complete, except for the Wideband bung (didn't come in)
Removed Oilpan, drilled pan and welded 1/2" NPT half coupling, installed
Mocked Turbo inlet pipe to filter
Cutout flange to cat (weird 3 hole pattern)
Mocked oil feed line
Gauge Piller Pod installed with Boost and NB o2

That's pretty much it for now. I'm going to try to have everything completed and installed this coming weekend! Remember I did all this but then put the car back in service as it's my daily driver.

I'll try to get some pics up soon.

-John

It's Alive.......Kind of. Well everything went as planned this weekend. The kit is complete and installed. Now for the fun stuff, I go to install my tune via the SCT X3 and everything seemed fine....until it starts uploading my tune and wammo....DOWNLOAD FAILED!!! And then it didn't let me upload the stock tune back!!!!!!!
After some head scratching and worrying I realized that the battery may have been drained from the trunk being opened all weekend. My battery was alittle weak to begin with so I guess that did it in. That said, this morning before work I was able to upload the stock tune back in and fired it up. I just let it run to cycle the coolant being I changed the thermostat.

I must say it sounds pretty good, the turbo seems to spool pretty quick off idle. I didn't drive it being I can't load my tune so I'll keep you guys posted later.

BTW..... Take a look [thumb]

looks good [thumb]

sweet! can't wait to see the results

the build is looking awesome! i saved all your pics of the turbo manifold for future use hopefully thats ok? i'd like to copy your design it looks elegantly simple!

looks good but are you starting it and running it on the stock tune?

I'll keep you guys posted with results, I'll start tuning and plan a dyno day when I get things close.

klodkrawler05, I may be willing to build you one if your interested. The whole manifold is 304L stainless and tig welded.

-John

Roushturboedzx3, yes and no. I started it but didn't drive it with the stock tune this morning. I realize that I can't drive it with the stock tune. In my previous post I said that I was having problems putting it back to stock and this morning I was able to download it back but wasn't able to upload my tune???[:(]
I spoke with SCT and they feel that a weak battery would cause those kind of issues that I was having, so off to buy a battery.

-John

Manifold looks great! Bravo. Your appreciate using a thicker tubing wall on that badboy, as I'm fighting a cracking Focus Power manifold now. grr..

I am also doing the custom turbo thing (http://www.focusfanatics.com/forum/showthread.php?p=2344436#post2344436) and with a T3 Super 60, Focus Power manifold/downpipe with AEM wideband, Autometer boost/egt gauges, intercooler and piping, -10AN drain hose and braided feed line, Greddy BOV and Evo wastegate, I'm well over 2700 let alone talking tuning and J&S. So to each saying that it can be done on 1400, it may well be, but nothing proven and well built.
first your telling him that his stuff wont hold up or be proven

Manifold looks great! Bravo. Your appreciate using a thicker tubing wall on that badboy, as I'm fighting a cracking Focus Power manifold now. grr..
now your saying its going to be better than your "tried and proven" stuff

not starting a fight just thought it was funny [wave]

No, I'm not questioning the craftsmanship of your welds, or your manifold. I really question the durability, or the overall quality of knock off wastegates, bovs, and turbos. The intercooler should be fine, although some will debate, but i've seen other makes and models of cars use ebay brands such as CXRacing and Mishimoto intercoolers effectively.

Don't qoute me. I'm not a big fan of that selective qouting pissing match type arguing.

klodkrawler05 thanks for looking out but I kind of understand were AerofurySC was coming from at first. I really hate to turn this thread into a pissing match. What matters in the end is if I accomplish my goal or not.

Another quick update[:D]

I drove it home (I did all the work at my folks house being that my father is the welder[:)] )...... anyway, WOW[driving]

I drove it very very conservative, shifting no higher than 3600-3800rpms. I also didn't lay into it, I only saw about 4-5psi of boost. All I can say is WOW. The turbo is very responsive from 2400rpm on. Tomorrow I'll get the wideband in the car and start with the tuning.

Thanks again and keep em coming....

-John

sorry like i said i didnt mean to start a fight i just remembered seeing that post earlier than saw that one to and it struck me as funny
like i said not trying to start a fight i think your work looks great!

rock the turbo!

keep us updated!

Wow this came together quick!! Very nice job on the welds they look great!

Haven't had much time this week for much but last night I was able to install the wideband.
1st off I have to thank some of the guys preeching against the Narrowband......Just a quick comparision last night, I'm sold!!!!!
That said I removed my narrowband and installed the Wideband FOR GOOD! So running the car at idle it seems ok, I would rather see it alittle leaner at idle (currently 10.9-11.2). Now for the tuning, it's running a bit lean all around during part throttle (14.4-14.8). If I do a 3rd gear pull from 2000 RPM lug to boost build (only 5-6psi) it stays steady around 11.8-12.2. I didn't have much time to datalog or tune but I have my work cut out for me.

Otherwise I went over the whole build as well, re-torque the bolts etc... I did run into a problem.
The knock off blow-off valve..... I was checking something on the vacuum line and I broke the nipple on the blowoff valve.[?|] So, I had a back up and installed that for the time being (off of a Volvo [:D] )

That's about it for now....

I have a question for the tuners out there. I know that the IMRC's should be disabled but I'm having a hard time understanding how the function works. I would like to disable the runners in the long position. Right now I set the TP_Rel at 1000 for the entire RPM range. I'm not sure if that keeps it short or long at all times. Thanks in advance...

-John

Not much changed, so far so good. I have about 150 miles on the kit.
Tuning...Tuning....Tuning,

I'm getting into this Pro Racer Pkg more and more, but I wanted to see if anyone out there with experience using the PRP was willing to look at my tune. I would like to compare tunes or have someone take a look to make sure I'm on the right track.

-John

I am sure 03OrangeSVT would take a look at it for you!

I'll look at it for you and if you're lucky I may tweek it a tad.

Do you have any 3rd gear datalogs from 2k to 7k (AFR allowing)??

Off the top of my head I would suggest you datalog the important stuff like

short term fuel trim
fuel pressure drop across injectors
rpm
load
throttle position absolute (in counts)
spark
air flow in #/min (NOT MAF voltage but actual air flow)

I'm sure theres something else... but I'm at work right now and I can access my laptop to see what else I usually log.

Are you running a J&S safeguard or are you still on the factory knock sensor??

03OrangeSVT, I'm not running a J&S still on the stock knocker. Yesterday I was able to spend some time on the car and was able to save one 3rd gear pull from 3K to about 6.8K RPM. I'm pretty sure that I logged at least what you mentioned if not more. Currently my tune is based from the SCT Blown file which I changed some. The Car runs fine, no hick-ups, stalls, etc. It's as smooth as it was stock, if not smoother but being new to the PRP format I wanna make sure I'm reading things right.

I'll send you a PM with the files.

Also does anyone know what the function is for a Autometer wideband. I hooked it up to the SCT but right now I'm reading voltage not AFR.

Thanks again guys.

-John

how it going?

Pretty good, I have about 1000 miles on the kit as of this week. Last week I pulled the downpipe off because I didn't use lock washers to the turbo DP flange so I lost some of the bolts.[?|] I decided to pull it so that I could reschmutz (high temp gasket sealer) the flange.
Anyway everything looks good with the turbo. My tuning is coming along but man is it time consuming!

Aside from that not much else for now.......[thumb]

-John

Well good I am surprised you have not had major issues. Congrats and hopefully everything stays together.

Have you really pushed the system yet? or is this 1000 miles in mostly vac?

Pretty good, I have about 1000 miles on the kit as of this week. Last week I pulled the downpipe off because I didn't use lock washers to the turbo DP flange so I lost some of the bolts.[?|] I decided to pull it so that I could reschmutz (high temp gasket sealer) the flange.
Anyway everything looks good with the turbo. My tuning is coming along but man is it time consuming!

Aside from that not much else for now.......[thumb]

-John

Have you picked up the J&S yet???

You REALLY need it before you melt your pistons... I'm serious, the stock knock sensor will add several degree's of timing when it thinks you need it and it will blow holes throught pistons.... just PM egbertnr and ask him about it.

Yeah this is what happens when the factory knock sensor adds timing....After doing this and looking back, 600 bucks for the J&S would have been a fraction of what I spent to rebuild.
http://i207.photobucket.com/albums/bb175/egbertnr/SVT%20Focus/IMG_1001-1.jpg
http://i207.photobucket.com/albums/bb175/egbertnr/SVT%20Focus/IMG_1005-1.jpg

o man, thats horrible

Are you doing all the welding yourself?
I'm just now looking into welding stainless, so I'd like more info on what kind of welder you're using, the size wire, heat setting, and gas mixture.
Great work!
I've definitely been tempted to try one of those ebay turbos but don't think will.
A friend of a friend (seriously) ran one on his car and it lasted less than a week.