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Old 04-01-2010, 03:13 PM   #1
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illinipo's "It's finally my turn" custom turbo kit build

I figured it's about time I get this started, the parts are beginning to roll in in a more serious manner. I've been around here for... a while. This turboing a zetec stuff isnt exactly new to me, but I could still stand to learn a thing or two.

Here is my car:

200,000 and counting :D

And a condensed mod list since I know only half of you will follow that link

MTX75 swap w/ Exedy OEM clutch
Torsen
Rally brake kit with Axxis ULT front pads
Koni yellow fronts, Bilstein PSS9 rears on Eibach pro-kit springs (wagons have progressive rear springs in the pro-kit)
10.5:1 compression with FR2 cams, Eibach valve springs, Supertech valves
3" intake with 3" maf, FC 65mm throttle, and the 2000IM
2.25" FS Stealth exhaust with JBA shorty and RT HFC and the 2.25 flex off of the old Goatmobile (only the OG's will remember this one!)
SCT Pro Racer tuned by moi
200,000+ miles

It's a pretty sweet NA build that I havent changed much for the last 3 years. I'm really happy with it. But I am bored.

Goals are to have a reliable kit with just enough power to barely have traction in 2nd gear and really good throttle response and spoolup. Plus I'm going to do some less popular things just to keep it interesting for me. This kit is not about making power or impressing the masses. I enjoy fab work and making problems for myself to solve.

Some of you may notice the high mileage and high compression. I just did a compression test the other day, it sits at 185 190 190 190. Before I tuned the intake cam and fixed my valve lash it was over 200 on all 4. I'm not too concerned about the mileage. I will be keeping the rev limiter at 6500 to avoid shredding my rods.

The compression will make things interesting. It will definitely help spoolup and off-boost response, but my timing is already pretty low at full load. If I end up having to go BTDC, I will have to go get a head out of a junkyard and go back to stock compression, or pick up a Cometic .065 headgasket.

Some parts I have already:
3" MAF tube that is on the car and tuned already
MAFia but I don't think I'll need it for the power I'm looking for.
35/38mm Turbonetics Evolution wastegate with 9psi spring
WG dump tube
1G DSM BPV (I may be switching this out for something else.) (Edit okay yeah im getting a SSQV knock-off and pulling out the bird whistle fins)
green giant 42lb injectors (not green tops) on the car currently tuning them

And stuff I need to get still:

http://docs.google.com/View?id=d83n6b9_3dfbz9wg4

If you looked through that link you would have noticed some AWIC parts. There pros/cons of AWIC/AAIC are well-documented. Here's my take: I don't like the look of a FMIC, and I really dont like all of that tubing. You can get much better response with shorter intake piping. So, my charge piping will consist of THREE pipes (90 bend, straight-through intercooler, MAF).

I will be using the auto trans cooler as my heat exchanger to start off. I know I am going to get a ton of slack for this, because people think you need this huge bucktooth heat exchanger hanging off your bumper. But, have any of you TRIED it? If it doesnt work well, I will upgrade. Again this is not some epic 500whp build so I really dont think I will need that much capacity.

A ton of factors went into my turbo selection (reliability, ball bearings, v-band housing availability, price, spool characteristics, high rpm characteristics) and I landed on the gt28rs. I know, it's based on 20 year old technology, blah blah blah. But you can't deny that it is OEM reliable, and does just fine for a 220-240whp build with room to grow later. Plus I am getting it for a REAL good price (I wish I could say but I cant). It took me a long time to pick it so I'm sticking with it.

So here is the first pic, these came in this week. Probably many more pics to come.




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Last edited by illinipo; 05-11-2010 at 03:24 PM.
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Old 04-01-2010, 03:25 PM   #2
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Your wagon is awesome. Can't wait to see this build take shape!
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Old 04-01-2010, 03:53 PM   #3
LETS TURN DIRT!!!!
 
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About time!!!!

Now get to work and get that thing turbo'd
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Old 04-01-2010, 06:57 PM   #4
I Fab Too Much
 
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I like the idea and am looking forward to seeing more ppl fabbing :)
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Old 04-01-2010, 07:18 PM   #5
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This is gonna be sweet. Remind me to be on the lookout for a blue wagon this summer if you're near me...
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Old 04-01-2010, 09:19 PM   #6
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good luck with the build...the tranny cooler/heat exchanger will do just fine just run a good fan on it...a tranny can put ALOT more heat into the atf than the turbo will put into the water to air cooler. the gt28rs is a great turbo and with a short pipe run will give you near instant boost. looking forward to see how this turns out..as far as the high compression a water/meth injection system such as an aquamist programmable jobbie should take care of that.
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Old 04-01-2010, 11:27 PM   #7
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Yeah meth is an alternative to the headgasket or head. It depends what I want to do with the car at that time. I hate the idea of always needing to refill the meth container, and if it runs out I blow my motor. The car will be seeing boost daily.

That was my thinking, that the atx puts a TON of heat in that oil. The cooler should be more than enough.
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Old 04-02-2010, 02:31 AM   #8
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so pete, i'm jealous. especailly since you are probably going to weld the manifold up yourself.
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Old 04-02-2010, 08:37 AM   #9
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Manifold, DP, and I'm even looking at some aluminum welding on the inlet for the BPV port.
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Old 04-02-2010, 09:03 AM   #10
Too old for this...
 
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Looks awesome man. Join the list of us Turbo Build people. Theres 5-10 of us.

Gonna be a bunch of new Boosted Foci this summer.
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