sporadic's Turbo Duratec build thread

[jrpasmo]

Why only 0.035 gap ? how much boost u planning to run ?

[sporadic]

Originally Posted by jrpasmo

Why only 0.035 gap ? how much boost u planning to run ?

Only reason is that's what Randy runs in his Focus Sport turbo kit.
The fab work I can do (which is the majority of this work)... it's the tuning etc I have to lean on other folks for, so I went by what Randy has on his website.
So when you ask "why", I don't know. Ask Randy. :)

Oh, and I'm running 9.5psi - the stock boost for the IHI wastegate.
No boost controller because I won't be straying from that.

[jrpasmo]

Hmmm I'm running around that same PSI with my Procharger...having them gapped to 0.055 no problem....just wanna let u know ....

[fokuzx3]

jeez youve put alot of hours into makin this thing happen, i think i would opt to go for the fs turbo lol ... seriously though, how much money you think you have saved by doing it yourself vs the 4k turbo kit?

[jrpasmo]

^^^ Just read his first post and u'll understand that is not about $...

"Doesn't somebody make a kit??
Yep. Randy at Focus Sport sells them for a mere $4,000.
I'd personally rather have no turbo at all than to spend that much, learn nothing, and barely lift a finger.
That's just not me.
"

[Bigfonsz]

Originally Posted by jrpasmo

Hmmm I'm running around that same PSI with my Procharger...having them gapped to 0.055 no problem....just wanna let u know ....

.55 that can't be right

[jrpasmo]

heheh read it one more time ... 0.055 ;-)

[sporadic]

Originally Posted by jrpasmo

heheh read it one more time ... 0.055 ;-)

Thanks much. I'll talk to LaSota Racing and see what he thinks and let you guys know.

[sporadic]

Originally Posted by jrpasmo

^^^ Just read his first post and u'll understand that is not about $...

"Doesn't somebody make a kit??
Yep. Randy at Focus Sport sells them for a mere $4,000.
I'd personally rather have no turbo at all than to spend that much, learn nothing, and barely lift a finger.
That's just not me.
"

You got it right, sir.
I'm having a blast and learning more every day.
It's not work if you're having fun.

[sporadic]

Day 9

Start time: ~5:30pm
End time: ~10:45pm

Dan finished up my oil pan a day early!
I'm quite happy with how the return tube turned out!
I ended up trimming it down about 2".

Today I got the oil pan reinstalled, and that's about it.
Cleaning the old oem RTV off took a while.
I cleaned the gasket surface about 3 times with mineral spirits before applying the new RTV and installing the pan.
The Haynes manual states to remove the transmission in order to remove the oil pan. I did not.
It was a tight fit, but it does come out and go back in without removing the tranny.
The only concern would be proper sealing of the pan against the timing cover.
I suppose I'll find out soon enough if I did it correctly. Seems ok at first glance.

I started removing the intake manifold.. man what a pain.
I'm revamping the stock PCV system so all air is from and back to the atmosphere.
That way the cruddy oily fumes won't gunk up my intake tract and at the same time throw off my tune.

Assumming all goes well my tune date is Friday August 3rd!
I plan on working like a mad man this weekend to get the car completed.

What's left (off the top of my head):
- Exhaust from the cat back, using mandrel bends but nothing is welded or cut to length yet
- Reassemble "good" turbo
- Route oil feed a return lines
- Splice into coolant lines and route to turbo (one of the last things I do)
- Install gauges and route lines. (Boost and Oil Pressure)
- Redo PCV system
- Reinstall and clamp intercooler piping
- Install base "no boost" tune


PICS

Oil pan with drain tube:
Before trimming the tube.
It's slightly below the oil line.


Pan with baffle installed:


Oil pan installed:


A couple of random pics of the test-fit turbo from beneath the car: