Xp0s3d's Churbotarged Build Thread - Focus Fanatics
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Old 08-17-2007, 02:33 AM   #1
xp0s3d
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Thumbs up Xp0s3d's Churbotarged Build Thread

25psi Turbocharged Built Sedan :-D


Hey Someone nominated me for ROTM, I need all your guys' help!!!

Listen to that baby growl!!!
http://vids.myspace.com/index.cfm?fu...deoID=19376518

(Cleaning water out of the charge piping after getting caught in the rain)
http://myspacetv.com/index.cfm?fusea...deoid=19297459


ENGINE MODS:
PnP Head (0.030")
HTPerformance.net Intake Manifold
Egl Rods/Stech 8.71:1 Pistons
Clevite Main/Rod Bearings
ARP Hardware
50lb Inj/MAFia/SVT MAF
Focus Central 65mm Throttle Body
FR Stage 2 Cams/FC Sprockets
180 Degree Thermo
Race Performance Clutches
2200rpm Stall Speed Torque Converter
Recalibrated Valve Body
SCT Xcal2
Kenne Belle BAP
Custom Log Manifold
.50/.63 TO4E Turbocharger
3" Downpipe/Exhaust
HKS SSQV BOV
Turbonetics Deltagate MK2
PWR Air-Water Intercooler
Ford Lightning Water Pump
Dual Pass Heat Exchanger

INTERIOR:
Dual Gauge Pillar
AEM Tru-Boost Electronic Boost Controller
AEM UEGO Wideband O2 Sensor

EXTERIOR:
Focus Central Spark Plug Cover
Custom Two-Tone Paint Job Black on Silver
Roush Front End
Amber SVT Fogs
Eibach Pro-Dampers
Intrax Supersport Springs
17" Motegi FF5 Wheels
Fuzion XRi Sport Tires


Precautionary Actions

Pulled head to clean out cylinders and make sure everything was running well since I built the engine.
Sorry no pics

Day 1.

Installed AEM Tru-boost, AEM UEGO, and Kenne Belle BAP
Sorry no pics

Day 2.

Pulled coil, looks like #4 blew out. Thanks MSD!
I love massive for overnighting me a new coil!!!


Tapped the head for some OIL


Goodbye longtubes, it's time for something NEW


The real way to get an oil pan off


The deed is done



Mmm oil drain



Manifold


Wastegate


Brand New 50/63 T04E


Fittin's


Dressed Turbo


Every good turbo needs some drink


What goes in must come out


Some 3" DOWNPIPE


This is starting to look like a kit!


Something's missing...


I know! Let's Add an Air-Water intercooler and some charge piping!


Puttin' in 50lbers


That concludes the end of official build day 1. Day 2 update tomorrow night :-)


---------------------------------------------------------------------------------------------------------------------------

Day 2, Last Day of Mechanical Work:

Mounted the heat exchanger for the intercooler (it's zip-tied, don't tell anyone lol)



That top water fitting is going to leak all over the garage floor, but don't tell Josh, he'll find out later that afternoon.


Look a filter!


The charge piping is making shifting the automatic very difficult, I don't know what I'm going to do about this problem yet


Put in new spark plugs (They're gapped at 50 and the car won't idle for shit, I need less fuel and a smaller gap I think)


Rigged it so I could drive it around and see how it ran (I was too lazy to set up the liquid cooling *shudders* liquid grr)


Ready to start it up, pulled the fuel pump fuse and spark wires (There's a video, maybe i'll put it on later)


Zip-tied the oil line because I heard it likes to melt things, doubt zip-ties will work for long under those circumstances lol...


Went to Tires plus. Apparently, brand new tires get nails in them too argh...


Tiresplus: Bytheway, ur leakin oilz (It's where the hose goes into the pan, I just had to tighten the hose clamp)


Bought ANOTHER reservoir and set it on fire AGAIN, I guess I'm just destined to use the SVT reservoir sitting on my desk


How the F am I going to fit this in...


This is in the way, lets move it closer to the intercooler (This made the BOV a LOT louder holy cow)


Ok it's in without kinking any of the hoses, this took an hour of moving everything around back and forth about an inch to get it all to settle perfectly


It's empty! Know what that means?


FILL IT UP FILL IT UP FILL IT UP


Ok, there wasn't enough teflon tape on the top fitting of the heat exchanger and it was dripped, so I go ahead and yank the hose off and dump WINDSHIELDWASHERFLUID EVERYWHERE.


Full house


That concludes your tour for today, next week, dyno tuning :-D

Driving the car this morning was TONS of fun. Right around 2k, the turbo starts whistling, and around 2.5k it starts building boost whether you're on the gas or not lol. I wasn't even on it and it was already pulling harder than it was when I had the JRSC pushing 12psi. I can't WAIT to get this thing on the dyno next week!!! I did a test-drive tonight with the cooling system all hooked up and I love having the blow-off right on the intercooler like that, it's a LOT louder. The car seemed more responsive with the cooling system in place also. Now I just have to get it to stop fouling out the plugs, maybe I need to raise the MAFia setting up?

UPDATE 10/1/07: Got the car running right yesterday!!! I made 25psi at 5600 rpms and let off the gas before I caused any damage haha. But HOLY SHIT!!!! HORSEPOWER!!! I can't wait to get dynotuned!!!!

UPDATE 10/28/07: Pricing out wheels and tires, looking at JEGS.com, G-Force T/A Drag Radial Tire P225/50R15, Sport Lite 8-Hole WheelDiameter & Width: 15 x 7", $520 shipped, mounted, and balanced.



Last edited by xp0s3d; 10-28-2007 at 01:07 PM.
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Old 08-17-2007, 02:43 AM   #2
Impaled
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showing love for the man who has never given up on his dreams, who has suffered through all of lifes challenges and has laughed in deaths face, a true man...my buddy josh.

i leave you all with this wonderful thread of perseverance and accomplishment.

and i say Josh i wish i was half the man you are.

love you buddy. good luck
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Old 08-17-2007, 02:44 AM   #3
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keep it coming everyone loves pics and build and lets not forget the lil' ole' turbo power
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Old 08-17-2007, 05:48 AM   #4
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Looking good!
Thanks for the pics! :)
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Old 08-17-2007, 07:11 AM   #5
rebelyouth
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Yeah man keep them pic and updates coming everyone loves pics
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Old 08-17-2007, 07:34 AM   #6
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Josh is at it again!

kudos
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Old 08-17-2007, 08:27 AM   #7
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nice man, that looks like the exact same turbo i'll be using. shoot me a PM i want to know where you got the DP or if you made it.
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Old 08-17-2007, 08:34 AM   #8
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http://www.focusfanatics.com/forum/showthread.php?t=131832
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Old 08-17-2007, 10:35 AM   #9
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nice. what kind of numbers are you shooting for?
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Old 08-17-2007, 10:39 AM   #10
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Very nice...What company makes the intercooler? I take it you aren't going to run a front mount?
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