sporadic's Turbo Duratec build #2

[sporadic]

Never a dull moment. It's very convenient having a spare motor to mock up things, but I forgot that I don't have any accessories on that spare motor! After I finished welding up the wastegate return and went to mount it on the car I quickly realized the wastegate is hitting the alternator! I could 1) cut and reweld the wastegate routes 2) grind down part of the alternator or 3) grind down part of the wastegate. The wastegate lost.
The side wastegate nipple was hitting the alternator, as well as about 1/8" of the aluminum housing (vac area not the steel exhaust route). This all actually turned out to be a blessing, as I found that part of the diaphragm was pinched between the halves of the aluminum housing. I disassembled the wastegate nearly completely in order to clock the housing so the nipple wouldn't hit the alternator. A bit of grinding later and it fits fine.





Wastegate ground. Please ignore the funky old welds on the manifold.


If only all my cuts were perfect then all the welds would look like this:




Fits now!

[sporadic]

All welding done and parts painted. I paint my welded exhaust parts to keep them from rusting too quickly. Some of my welds from 5 years ago had not rusted yet after painting them. Painted with 1200* grill paint and cured on the grill. The only thing left in Phase 1 should be routing the water lines, mounting everything and checking out the tune. I hope to wrap up tomorrow/Wednesday.

[sporadic]

Turbo is on and no apparent oil, coolant or exhaust leaks. Tomorrow after work I'll do some datalogging and adjust the tune as necessary. I didn't get a chance to drive it today, just let it idle up to temp to check for leaks.

[Roushturboedzx3]

Its great when there no leaks etc

[sporadic]

The turbo is on and spooling and running fine with zero leaks. This is actually the first time my car has not had exhaust leaking from somewhere.
The bad news is the wastegate spring is only 6psi instead of 8psi, so it wasn't a very exciting drive. The tune is overly rich since dropping from 11psi to 6psi, but I'll touch that up a bit until I get a new spring or boost controller. More pics to follow.

Next project is the house, not the car so it will be some time before I get back to it.

[sporadic]

I believe I determined I have a 7.2psi spring in the wastegate. I had the spring out twice and I'm fairly certain it was green. HERE is the guide from Tial. I would have sworn the boost gauge didn't go above 6 though, but I guess I was trying to watch a lot of things a the same time.
I'm not sure if I'll go with the 8.7psi or the 10.1psi spring. Probably the 10.1psi...
EDIT: I believe the difference in boost readout is because I have my boost gauge referenced off the manifold and the wastegate gets its pressure off the compressor housing.

Installed photos:

Without manifold heat shield


With manifold heat shield (modified stock heat shield)








Sorry no decent under-car photos. I tried to take some tonight and it just didn't work out. Next time I'm under the car in the daylight I'll take some.

Overall I have to say I'm extremely happy with how smoothly the build went. I am also a firm believer in v-band clamps now!
I've only had it out for one drive to help dial in the tune, so I can't really comment yet on how fast the turbo spools etc. I should have more input after this weekend, and my also post data log info.

[Turbo Turtle]

do you have your wg referenced to the IM or the compressor housing?

[sporadic]

Originally Posted by Turbo Turtle

do you have your wg referenced to the IM or the compressor housing?

I put that in an edit above: wg references the compressor housing and boost gauge references the manifold, so the difference there is the pressure drop across the piping/intercooler.
Another guy pointed that out to me. I really should have thought about that.

[Djzx3]

Did you get ARP studs for the header?

What's the size? 8 X 1.25?

[K26]

Got any video of this man?