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Old 07-26-2007, 02:33 AM   #31
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Good Stuff
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Old 07-26-2007, 09:03 AM   #32
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With that 0.055 I'm running screaming demon coil + live wires...I forgot to tell...many people hates them here,but I can't tell anything bad about this confg. yet
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Old 07-26-2007, 07:59 PM   #33
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wow..... wow.... you are an inspiration... ive been tosing the idea of building my own turbo lately...

i will deff. be watchin this thread! i only wish my dad would get off his butt and buy a welder! lol and then i can start collecting parts and take the last of my vacation for this year and work on my car! lol

good luck!
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Old 07-26-2007, 11:05 PM   #34
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Thanks everyone!
I talked to my tuner and he said to go with .035" gap for my plugs, and that I'd get spark blow out with .055".

Day 10

Hard to believe I've been at this for 10 days now.

Start time: ~6:00pm
End time: ~11:15pm


Today I said goodbye to my PCV system.
I'll be running no true PCV valve, but a modified PCV valve with no valve. (see pics)
I cut the very bottom off the stock PCV valve, which exposed the metal valve and springs which fall right out.
Air now flows freely though the uh, un-valve.
Both the valve cover and crankcase hoses will run to a catch can with a breather filter on it.

I'm still deciding whether or not to "Y" the two hoses into the same port and use the 2nd port for the breather valve, or drill and tap a hole in the top and add a 3rd port for the breather filter.
Opinions welcome.

Intake manifold removal tips:
- First thing, assuming you have an air compressor, blow out all dust and dirt away from the manifold and surrounding areas.
You really don't want junk falling into the head.
- Have an extendable magnet handy. Makes reinstalling the bolts much easier, and for grabbing the bolts when removing so they don't fall to unreachable places.
Also great for when you drop the 10mm socket, the 6" extension, or both.
- All the primary 10mm manifold bolts can be reached with a straight 6" socket extension.
No bendy knuckles needed, as I tried to begin with but just made it harder on myself.
- Back out the 2 10mm bolts on the fuel rail at least 1/4". This provides necessary wiggle room to remove the intake manifold.
- Save removal of the knock sensor bolt until after the manifold is unbolted. Much easier to reach.
- Plug the knock sensor electrical connector back in before bolting up the manifold.
- Don't forget to reinstall the little copper tube for the EGR.. unless you just like practice removing and reinstalling the manifold.
Yes I did that. :wallbash:


PICS

Intake manifold removed.
The blueish thing near the center of the pic is the PCV valve.


Underside of intake manifold.
The round blue gasket on the far left seals around the EGR port.


PCV valve.
It's possible to remove the valve without removing the black cover, but removing that cover makes it much easier.


Black plastic cover removed:


EGR port. Sans copper tube.
Copper tube must be removed to remove intake manifold.


Back side of black plastic cover with PCV valve installed.


Stock Duratec PCV valve.
The little black plastic retaining ring is a pain to remove.
I managed not to break it, but it's fairly fragile.


PCV valve with bottom cut off.


Contents of PCV valve, in order.


Intake manifold port plugged.


New PVC hose installed but not trimmed yet.
Catch can isn't mounted, so the hose isn't running to anything yet.


Knock sensor.
It's the thing in the middle that's not bolted yet.



Next:
- Exhaust
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Last edited by sporadic; 09-05-2007 at 10:10 AM.
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Old 07-27-2007, 12:28 AM   #35
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This is an awesome looking project. I wish you the best of luck on this. It looks like it will turn out great.
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Old 07-28-2007, 01:36 AM   #36
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Day 11

Start time: ~7:00pm
End time: ~1:30am


Well I was hoping to finish up the exhaust today, but I'll have to finish up tomorrow.
My plan was to just work through the night but I'm too tired.
I have most of it done, just the last angle left to do and then fully weld the tack welds.
Since I'm using flux core wire I'll be painting the exhaust, even though most of it is stainless steel.
The "tip" will not be painted, but instead I used the wire wheel on my bench grinder to polish it.

The exhaust is completely from scratch..
The mandrel bends are "seconds" from www.mandrelbendingsolutions.com.
They sell seconds for $5/bend for aluminized or $7/bend for stainless steel.
Don't take this price as gospel though. If they change it they change it.
All of the hangers I'm having to fab too.
It would have been far easier to purchase a cat back, but if you haven't noticed I'm a bit stubborn like that.

I plugged the hole in the EVO section of my air intake.
A cap from a mini can of WD-40 fit absolutely perfect.
Hey, sometimes you have to improvise! :)

Not many pics today..

PICS

WD-40 cap in intake:


Exhaust:


Polished but dirty stainless steel "tip":
3" is plenty big enough of an exhaust tip.


1 of 5 custom hangers I have to make:
I'm using a 3' section of 3/8" round steel that I cut into pieces.
So far it's working great, but tedious work.


Goals tomorrow:
- Finish exhaust
- Assemble turbo
- Run oil lines
- Clamp intercooler piping

Sunday:
- Coolant lines to turbo
- Install gauges
- Load base tune
- Other stuff I've forgotten about

An ambitious schedule for sure!
I really want my car on the road Monday, and tuned Friday.
For now, I need sleep!!
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Last edited by sporadic; 09-05-2007 at 10:10 AM.
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Old 07-28-2007, 01:44 AM   #37
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Dude, you are a pioneer. When are you going to start building foci for a living?
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Old 07-28-2007, 06:33 PM   #38
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Anymore, when I need motivation to get my lazy butt outside to install/fix something, I just skim this thread. It's amazing what a bit of creativity can accomplish.
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Old 07-29-2007, 01:40 AM   #39
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Day 12

Start time: ~11:00am
End time: ~1:30am

I finished up the exhaust today.
It took way, way longer than I anticipated.
Getting everything aligned just right by myself, on the garage floor, and making my own hangers from scratch was pretty tough.

I ran into an alignment problem with the IHI wastegate.
Apparently I had the test-fit turbo all tweaked and didn't even notice it.
So tomorrow I have to figure out a way to get my good one aligned properly.
I needed the compressor outlet to face a different direction than on the Tbird so I turned it.
I'll post tomorrow what I come up with.

I also weighed parts today since I'm basically finished with all fab work.
Measurements are with a bathroom scale, so accuracy is definitely not dead on.
Stock:
Exhaust: 31.4 lb
Header: 17.4 lb
Plastic air intake stuff: 7 lb
Total: 55.8 lb

Turbo:
IHI turbo: 12.8 lb
Header: 9.4 lb
Down pipe: 5.8 lb
Cat: 6.4 lb
After-cat: 23.2 lb
Intercooler: 8.4 lb
IC pipes: 15.2 lb (steel and painted)
Total: 72.8 lb

Total does not include weight of couplers, clamps, air filter, oil lines, brass fittings, gauges, and intercooler.
Estimated added weight: ~40 lb

PICS

Mid section of exhaust:


Cat with new hanger.
Looks odd but works great.


Full exhaust painted:


Wastegate misaligned!
Life goes on, will fix tomorrow.
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Last edited by sporadic; 09-05-2007 at 10:13 AM.
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Old 07-29-2007, 07:26 AM   #40
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looking good man. i need to paint my exhaust.
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