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Old 07-29-2007, 10:43 PM   #41
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Day 13

Start time: ~2:15pm
End time: ~10:00pm

Well I didn't finish today, but I'm definitely getting close.
Tomorrow would be nice, but Tuesday night is looking more realistic.
Most everything remaining now is assembly. :)
The toughest thing left is installing the gauges, and I don't think that will be too bad.

So all fabrication should be complete as of today.
The last thing I had to weld was a short piece of 5/8" OD stainless steel tube to the stock Tbird oil drain flange.
I think I had a bad ground and therefore my welds don't look as pretty as they should.

The big thing today was modifying the IHI wastegate actuator bracket to fit the wastegate arm as it should.
A couple new holes drilled and a part ground down and now the fitment is great!
I didn't think to take a before and after pic.

I assembled the turbo today including the 1/4" NPT piping for the coolant lines.
One runs pretty darn close to the exhaust inlet so I'll be watching that line closely to see if it needs insulated.

As for gaskets, I ended up not using one between the turbo and the compressor housing.
A guy from the Tbird forums, Sluggo, was nice enough to send me some IHI gaskets.
I was able to use the one for oil drain flange. Thanks!

I also installed the catch can.
I'm not sure I like the setup, but it's going to stay like that for now.
I didn't have the space I thought I did.
Oh well, it might end up working just fine and I never touch it again.


PICS

Oil drain line:
Flange is the stock IHI, minus the flex metal tubing.


Assembled IHI turbo


Here you can see how much better the wastegate aligns.
It's disconnected on purpose until I arrive at LaSota Racing for my dyno tune.


Oil catch can:
I'll take a couple more pics of it tomorrow.
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2006 sonic blue zx5 GT2871r turbo.

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Old 07-30-2007, 12:12 AM   #42
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This is simply beautiful.
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Old 07-31-2007, 12:34 AM   #43
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Thanks for the complements! :)

Day 14

Start time: ~5:30pm
End time: ~11:45pm

Oil pressure and boost gauges are installed!
That took the majority of the evening.
My oil pressure gauge line is copper, and that proved to be annoying to deal with.
Unless your local drag strip requires a metal oil pressure line I recommend nylon/plastic.. it's so much easier to route.

I remounted my intercooler and upper IC pipe, and tied in the boost gauge.

I wanted to get the turbo mounted tonight, but found out I can no longer fit the turbo from the underside of the car since adding the coolant fittings.
I have to remove the turbo manifold, set the turbo in, mount the manifold, and then mount the turbo.
I stopped on the last couple nuts of the manifold because of the time.
I nearly rounded a manifold nut.
Being this close to complete I was getting nervous... but it finally came off nicely and I even had another spare nut that will take it's place.

I still feel tomorrow could be the day, but it will be a busy evening for sure!

What's left:
- Mount turbo manifold
- Mount turbo
- Clamp IC pipes
- Clamp ambient pipes and make hanger of some sort for air filter end.
- Install exhaust. Still need to tweak one of the exhaust clamps for proper seal
- Oil feed and return lines. Return line is super easy clamp on. Feed should also be simple.
- Coolant lines. Also easy. I'm tying into the heater core feed and return lines and because of the angle of my car there's no coolant in them. :)
- Load base tune

Sounds like a lot but most should go quickly.

PICS

Another shot of the oil catch can:


I routed all lines through a hole in the door frame and wrapped them in a simple plastic wire loom.


Oil pressure gauge line:


Visible section of the copper oil pressure line is taped with electrical tape.
I just couldn't take the ugly copper line!


Boost gauge line mounted in upper IC pipe:


Pic of the gauges...
Better pics later.


Turbo with custom 2.5" ambient elbow mounted:


Different angle:
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Old 07-31-2007, 08:57 AM   #44
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looks like it's comming along nicely, can't wait to start mine,1 more month to order my manifold, after the wedding. this is a very inspireing thread. good job!!
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Old 07-31-2007, 07:07 PM   #45
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OK Turbo guys I have a question!

My turbo is mounted and the oil return line in place.. I thought I'd "prime" the turbo with oil before hooking up the oil feed line.
I expected the oil to drain right out, but instead only about 1 teaspoon went inside and didn't drain out!
It bubbled a couple times but didn't seem to be in any hurry to drain.

Is this expected?
Does there have to be pressure on the feed side for the oil to drain out?
If so that makes sense so the turbo isn't starved for oil on startup.
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Old 07-31-2007, 08:18 PM   #46
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Did you try spinning the turbo after the oil went in? Maybe that will do the the trick.
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Old 07-31-2007, 09:58 PM   #47
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Yep I spun it. I got my answer from a guy on FJ.
He says that's normal and oil won't pass through until under pressure, which makes perfect sense.
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Old 08-01-2007, 02:59 AM   #48
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Car is together.
Too tired to coherently install the base tune tonight.
Will do a full update with pics tomorrow night.
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Old 08-01-2007, 06:49 PM   #49
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IT LIVES!!!
Of course the wastegate is disconnected so there's no boost.
I'm heading out for dinner and some heat wrap. I'll post more later!
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Old 08-01-2007, 07:29 PM   #50
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^^^ yay, i can't wait
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