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Old 03-05-2006, 10:22 PM   #1
bluballer
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Talking Low Budget Homemade ZX3 Turbo Setup (On and Spooling!!!!!)

I saw this thread and said to myself basically I 'm doing this too (~$500 turbo kit). I'm doin' it a little different though ....Got it mounted and spooling going to the muffler shop this week ( down pipe :-) ). I will post pics and price list soon... P.S. mine is a T-3 setup using the GET THIS .....STOCK MANIFOLD MODIFIED ...To mount the T-3. I am going for mild boost 8lb w/no lag using a RELIABLE internally gated SAAB Turbo (oil and water cooled), a Volvo intercooler with a volumetrically matched electric cooling fan (for reducing idle related heat soak), To feed it I am using 42lb injectors and a matched 70mm Pro Mass unit.... Its a slick simple low cost setup that if it works correctly will push the envelope for DIY turbo setups for the ZX3 FOCUS!!! No disrespect TOM I LOVE YOUR (S_ IT) This is just so I can learn for myself. NEXT time you get my money ....engineering asystem that works correctly and low cost is hard work (respect)!!!! LOL and Tom, I'mma need some tuning too please so HALLA @ a BLU-BALLA!!! Can we work together on this thing?




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Last edited by bluballer; 03-28-2006 at 09:26 PM.
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Old 03-05-2006, 10:34 PM   #2
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Wow, from what I see, looks like pretty deent work. Did you do all of this yourself, the custom fabrication and stuff?
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Old 03-05-2006, 11:09 PM   #3
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if you get it working write up a how too that would be awsome for us on a budget
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Old 03-06-2006, 12:10 AM   #4
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I will give credit for getting this far. Do you have gear to measure AFR and EGT? If not, don't boost it at all till you get a tune. You have no idea what its doing.
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Old 03-06-2006, 12:50 AM   #5
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Never seen a top mount intercooler in a focus (minues the WRC car). I'd like to see a write up on it also.
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Old 03-06-2006, 01:27 AM   #6
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awesome, budget turbo systems are taking off. i bet were gonna see alot more of these in the future
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Old 03-06-2006, 02:02 AM   #7
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dwdgsi03 believe it or not there is not much fabrication to it.....the greatest of which what the manifold mod. Im not a welder... but a decent one can do it relatively inexpensive.

I did design/manufacture the brackets (very reasonable) and engineer the system. Because of the intercooler location the pipes are straight line (straight pipes). The blow off valve fits on a preformed pipe so no special molding there. It's connected with silicon elbows and connectors.

viney266 I do have all the required gauges and will try not to boost unless I know whats going on. I agree with you I really need to know whats going on ....LOL I'm lazy I dont wanna swap to a built engine yet!!!! And TOM (if you help me I Love you man!!!!! ) on that tune!!!

And rockthezx3 You are right I hadnt seen top mounted intercooler before that much either but I did see some Wide bodied Foci (red and yellow) that had an air to water intercooler in the same spot. Looked so sweet to me so I had to have it. Some like'm great big but for the boost amount Im trying to achieve, that intercooler came off a car with the A. same size engine using B. the same size turbo running C. the same about of boost. so for me that was a no brainer....if it works reliably and efficiently on Volvo's and SAAB's it for 100's of thousand of miles it should work for my meager application here too. The only thing I had to do to put it there was to relocate the battery to the rear "boot" where it belongs (as on many european cars)

I've also gone through the additional detail of putting a electric fan on the bottom side that will flow the maximum required volume of air through it at idle. ( I used the intercooler core size/flow calculations to find my correct fan.

Speaking of European ..... I've got a WRC style front clip (Ibherdesign) special ordered from EUROPE along with other European Body Mods (Portugal, England, Germany) that I'm going to incorporate into this one of a kind EuR-A-FoCuS!!! and the A is for American!!!!

Much more on the way but thank you all for support so far.....I was glad to hear it spool and see no smoke!!!! Keep ya fingaz crossed for me on the downpipe... gonna be a tight fit....

HALLA@ a BLU-BALLA!!!!
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Old 03-06-2006, 08:05 AM   #8
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How are you getting outside air to the intercooler???

Seriously it needs ALOT of fresh air blowing through it.
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Old 03-06-2006, 09:04 AM   #9
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Quote:
Originally posted by 03OrangeSVT
How are you getting outside air to the intercooler???

Seriously it needs ALOT of fresh air blowing through it.
actuallyonly running only 8 lbs he doesnt need an intercooler at all. 9 lbs is teh common threshold for intercooled or not. and if i read right he said he is putting a fan on the intercooler kinda like a b+m tranny cooler setup
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Old 03-06-2006, 11:09 AM   #10
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Egggggggggggzactly lg03focus additionally Im going to have a vented (EVO I think its called) hood that will provide a flow through location close if not exactly atop where my intercooler is located (a lot of thought and research went into my concept before I bought the first piece)..... This is not going to be some 500 hp, eat a Vette Monster.... (If I keep the car till I want a rip snorting monster I'll build an engine and go with a Tom's or equivalent setup )..... I just want something that suprises (stealthy and compact) and is commensurate with the eventual styling of the vehicle, and that I can use my otherwise stock (might add LSD to make it stickier and a stronger clutch when I burn this one up) drivetrain with .... plus im going to get the air from the same place that a volvo or a saab would get it .....and I dont think either has a huge front mout ic on 8lbs of boost either.

In fact my 84 SAAB turbo (with the original engine, factory APC tunning and turbo 186,000 miles no leaking or burning oil ) runs like a BULL reliably with NO Intercooler.....I'm convinced and will say it again though it's been said many, many, many, many times before .....for this car "It's all in the tuning" ....the physics is there and has been done and tested......everyone can achieve boost...... but the technology is definately in the tuning...... If I can achieve ~200 whp reliably with a low cost (hoping for less than a $1000) per smiles technology ....My Job is DONE!

O and if anyone is interested..... This link shows the first tuner car I poured everything into 1990 Acura integra.... she got totalled when an idiot ran a red light and caved into my side.... The focus is replacing it for now http://www.cardomain.com/ride/339883 not bad for a piece of crap I had to have towed home initially!!!! some of my other build ups are linked in the favorite links portion of that page....
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Last edited by bluballer; 03-11-2006 at 03:34 PM.
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