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Old 09-20-2010, 11:32 PM   #1
Jgrove998
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Thumbs up Jgrove's ST Boost Build

Final numbers on page 7. Pics and vids from McNews on page 8.

Well I thought I'd start a build thread for my boost project. I will use this thread to document my progress, ask questions, answer questions, etc. I don't mind criticism or advice but I don't want to turn this into a flaming thread. Not all images I will post will be full size; just click on them for the full size image.

Link to my photobucket album: CLICK!

So the background....

Over a year ago a fellow FF member was selling a turbo kit on here. I messaged him and after a few months of negotiations back and fourth we finally settled on a deal and my turbo parts arrive. This kit consists of mostly all the major parts from the F2usa original turbo kit including...
  • Cast style manifold with jet coating
  • 2.5" downpipe w/ integrated flex and jet coating (could possibly be 3" to 2.5")
  • Master Power turbo (Used 6 months, no shaft play, brand new exhaust housing)
  • .47 A/R Exhaust side , .42 A/R Compressor side
  • Internal wastegate (~8 psi spring)
  • Turbosmart dual port BOV
  • Turbosmart manual boost controller
  • 3" MAF sensor housing
  • 42lb injectors with harnesses
  • IAT sensor (For running a suck-through MAF sensor setup)
  • Misc. piping, couplers and clamps
  • SCT xcal2 with tunes
  • Gaskets for turbo
  • Oil feed and drain lines



I purchased separately...
  • AEM wideband
  • Glowshift boost gauge (will probably upgrade to Autometer for accuracy)
  • Glowshift oil pressure gauge w/ sender
  • Glowshift oil filter adapter plate for gauge and oil feed
  • FMIC (used, a very solid piece)
  • Universal intercooler piping, couplers and clamps (2.5")
  • 3 gauge, A-pillar pod
  • Autolite 103 spark plugs




Gauges originally installed in the '05


I originally planned to install this kit on my first focus, 2005 ZX4 SE w/ auto trans. But school started back up before I could install anything so I just sat on the kit until I had the money. I thought about selling it many times. Over this most recent summer I purchased a 2007 ST. Wow, what an upgrade and my turbo parts still fit! So I will be installing this "kit" on my ST, 2.3L Duratec. The best part is my xcal2 works with my new focus because the stock tune was reloaded by its previous owner.

I have been sitting on this kit for well over a year. I've done hours of research and have a pretty good idea of what is going on. I'm no expert but feel I have the ability to tackle this myself. I have read through many custom build threads multiple times to pick up all the tips and tricks.

Additional Info
-Although I've heard plenty of bad things about Master Power turbos mine is practically new; so I'm going to give it a go and see what happens.
-Tuning: I've went to Tom for plenty of questions about my build over the past year. But I've decided that since I am so close to McNews in PA, I will have my car tuned by them on the dyno.
-I am a full time college student and a full time intern so my time is very limited anymore
-This build will be happening over the next 1-3 months so bare with me :)


Turbo tease...



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'86 XR4Ti ; 2.3L Turbo, 15psi
1988 F150 Custom
'07 ST ; formally bewst'd - R.I.P
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Last edited by Jgrove998; 11-16-2010 at 11:34 AM.
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Old 09-20-2010, 11:42 PM   #2
Jgrove998
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Day 1: Intercooler Install

I wanted to get the intercooler installed and piping mocked up since I am using an universal kit. My good buddy Tom (PSUrivie) from my work gave me hand with this.

I am going with a blow-through MAF setup which puts the MAF sensor before the throttle body and after intercooler. The BOV will be setup before the MAF sensor so I can vent to atmosphere.

The front bumper was very easy to remove; kind of surprising IMO. Anyways, onto pics.






Then came the piping. Having the universal kit is very nice. I will have to pick up one more piece to complete everything.

Outlet of intercooler to MAF sensor. BOV will be mounted here. The clamps on the 90* elbow will be replaced with the t-bolt style ones.


Inlet of intercooler from turbo...


MAF sensor pipe to throttle body. I am buying a 180* bend pipe and trimming it down so I have one solid pipe in between here.



I'd like to thank my buddy Tom (PSUrivie) for helping me out with this. We took our time, double checked everything and the fitment perfect. I was able to put all the stock parts back on including the bottom splash shield. I am very proud of the work we did!
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Last edited by Jgrove998; 09-21-2010 at 11:21 AM.
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Old 09-21-2010, 08:29 AM   #3
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Looking good man! Where are you doing this? Let me know if you need another hand.
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Old 09-21-2010, 11:20 AM   #4
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Quote:
Originally Posted by SMITHBOY76908 View Post
Looking good man! Where are you doing this? Let me know if you need another hand.
Thanks! The intercooler install took place in my garage at home in Clear Spring. I had to button everything back up to drive back down for school during the week. Thanks for offering your assistance!

Quick questions though....
1. Where did you get your boost reference from on your '07 for the BOV/boost gauge?
2. Did u modify your PCV system at all?

I've been doing a lot a research on how to properly set up the PCV system with a boost application since the manifold will be pressurized instead of always in vacuum.
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Old 09-21-2010, 11:29 AM   #5
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i like builds like this. nice to see some one building their own kit for the duratec. not to many people doing it and posting it up. besides... sporadic (i believe) who also has a nice diy kit
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Old 09-21-2010, 11:32 AM   #6
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Quote:
Originally Posted by Turbo Turtle View Post
i like builds like this. nice to see some one building their own kit for the duratec. not to many people doing it and posting it up. besides... sporadic (i believe) who also has a nice diy kit
Thanks also! I've read through sporadic's build over 10 times LOL! I'm trying to make this build as clean as possible.
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Old 09-21-2010, 12:31 PM   #7
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This kit is coming together REALLY nice. It is going to be a CLEAN install. Grove has done his research and it shows. When your ready, man, we're taking the ST and the '09 to McNews!!!!
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Old 09-21-2010, 02:01 PM   #8
Jgrove998
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Quote:
Originally Posted by PSUrivie View Post
When your ready, man, we're taking the ST and the '09 to McNews!!!!
The drive home is going to be a fast/crazy one
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Old 09-21-2010, 02:08 PM   #9
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Looks good!
I'll be in Hagerstown at Mason Dixon Dragway this Friday the 24th.
It's a track rental, but I believe spectators/visitors are OK if you wanted to swing by.
I'll be there from 4:30-8:30.
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Old 09-21-2010, 02:30 PM   #10
Jgrove998
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Quote:
Originally Posted by sporadic View Post
Looks good!
I'll be in Hagerstown at Mason Dixon Dragway this Friday the 24th.
It's a track rental, but I believe spectators/visitors are OK if you wanted to swing by.
I'll be there from 4:30-8:30.
That's sick dude! For the Volvo company day? It'd be sweet to come out and see your setup and watch you run. I'll bring the camera and tripod for pics/vids. I'll PM you.
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