The Project Pad

Chris, can I upload the picture you sent me, I feel you they deserve a bone or something haha

...do it.

Please do?

COMMON! The suspense is killing me!

haha Corey, go ahead

I literally JUST got home from installing the Holset. I will update more tomorrow, but I'll just say the install went almost flawlessly and it looks effing MEAN. It took us two full days to get it all done. Had to make a new downpipe, tucked the exhaust up as high as it can get which is a huge improvement over before and its perfect, spent a LOT of time mounting the intercooler and getting that perfect, and then making all of the pipes for it.

The only problem that I didn't forsee was the oil return where it goes into the pan. I had a straight fitting on it and that hit the alternator. Put a 45 degree fitting on it and now its perfect.

No leaks, no rattles, and NO SMOKE from the Holset!! It has performed flawlessly so far. Still waiting on injectors and such, so we went out and tuned the car (at 1:30 am after we buttoned everything up) on as low boost as possible. The wastegate limits it to 6 or 7 psi (VEMS was showing around 150kpa which is 7psi) right now and that's perfect. At that boost pressure, I have to have the rev limit at 6500 or it starts to run out of fuel.

Right now with no boost controller hooked up, I see 5psi by 3200 RPMs. With a boost controller hooked up, I expect that to improve even more and climb quickly thereafter when I have the fuel for it. I have to say at 5-7psi its rather slow lol. Its a whole different car. Used to be able squeeze on it at 2500 and feel full torque. Now its got no guts below 3k...as expected of course. I simply cannot wait to turn the boost up. I can tell its going to be a lot of fun.

I got plenty of pics and will take even more and post them tomorrow evening.

Overall, I'm ecstatic! Couldn't ask for more at this point.


Oh, and thank you guys SO MUCH for supporting me. I couldn't have done it without you all!




-Chris

w00t!!!!

NICE!!!!

Well, I had my first issue today. Was gettin' it thru the gears a little. 6psi Woohoo! haha and then I went to get on it again and nothing. I was like ah shit, I was just talking this turbo up last night and now it shit itself. Then I noticed that it sounded like I had ITBs or something so my next thought was coupler came loose at the TB. Parked it at work, popped the hood, and sure enough the damn coupler came off :x ...to me relief though.

We weren't able to use the Hargetts on the install because we figured it'd be a good idea to wait until after the intake manifold is done so we don't have to weld them all twice and make 'em ugly.

loxxrider wrote:haha Corey, go ahead

I literally JUST got home from installing the Holset. I will update more tomorrow, but I'll just say the install went almost flawlessly and it looks effing MEAN. It took us two full days to get it all done. Had to make a new downpipe, tucked the exhaust up as high as it can get which is a huge improvement over before and its perfect, spent a LOT of time mounting the intercooler and getting that perfect, and then making all of the pipes for it.

The only problem that I didn't forsee was the oil return where it goes into the pan. I had a straight fitting on it and that hit the alternator. Put a 45 degree fitting on it and now its perfect.

No leaks, no rattles, and NO SMOKE from the Holset!! It has performed flawlessly so far. Still waiting on injectors and such, so we went out and tuned the car (at 1:30 am after we buttoned everything up) on as low boost as possible. The wastegate limits it to 6 or 7 psi (VEMS was showing around 150kpa which is 7psi) right now and that's perfect. At that boost pressure, I have to have the rev limit at 6500 or it starts to run out of fuel.

Right now with no boost controller hooked up, I see 5psi by 3200 RPMs. With a boost controller hooked up, I expect that to improve even more and climb quickly thereafter when I have the fuel for it. I have to say at 5-7psi its rather slow lol. Its a whole different car. Used to be able squeeze on it at 2500 and feel full torque. Now its got no guts below 3k...as expected of course. I simply cannot wait to turn the boost up. I can tell its going to be a lot of fun.

I got plenty of pics and will take even more and post them tomorrow evening.

Overall, I'm ecstatic! Couldn't ask for more at this point.


Oh, and thank you guys SO MUCH for supporting me. I couldn't have done it without you all!




-Chris

Attachment ( 22768 ) : 0725100327-00[1].jpg

nice work Chris!!! Eff, that's another 200 with a big turbo - I gotta hurry up!

DAMN!!! THats coo bro!

Damn right you gotta hurry Caset. I can't wait to see another 200 with a serious turbo on it

Everyone that stopped by the shop was like, "Holy turbo!"

Damn dude! That's awesome!! Way to go man! We need some pics ASAP!

noice

Looking good Chris, can't wait to see how it does with a proper tune.

I should also mention that the car sounds different now. Must be the bigger exhaust housing. It sounds kinda more S1-ish... :woowoo:

Also, a NA 3B is slow as hell. I could only hope that its not the equivalent of a 7a.

loxxrider wrote:Also, a NA 3B is slow as hell. I could only hope that its not the equivalent of a 7a.

With the low compression ratio I'm sure that the 3b is slower.

its gotta be. Its truly a dog that way lol. Its also probably got 500 pounds on a small chassis car.

atleast 500 pounds check the weights of 200 tq vs 4kq even adding a bit of weight to the 4kq for the turbo gear

7a = B3/Typ 89 but yeah the Typ 44 will be heavier.

SWEEET Chris! Nice work!!! Can't wait to see more pictures of the set up!

Alright, here are some of the pics.

*Disclaimer* I cleaned a lot of the mess in these pictures up this afternoon. I moved the coils over to the intake manifold side, changed some vac. routing, etc., etc. so its so much better now. I'll have to take pics of it later this week. This was at like 1:30 in the morning, so I just wanted to get home! I had to get up for work at 6. Also, Tom's TIG took a shit when we started welding. Needs a new torch in a bad way. The line to the torch started smoking when we tried to hit the thick intercooler for some brackets.

I don't have pics of everything of course because I was too busy with the car, but I got enough. I'll try to outline what we went thru for the build as a whole.

First order of business was stripping the car of its boost components. To my surprise, everything came off really easily. No rust is effin awesome. Didn't even have to use any PB Blaster at all.

Off came the stock IC piping and IC, then started unbolting manifold, turbo, lines, and downpipe. All of it was relatively easy but time consuming as always with turbo manifolds and their related components.

Got 'er down to nothing and proceeded with mock fitting the new turbo and manifold. Got the manifold on with a little help from the pry bar (not much needed really, but it helped) with the turbo attached and all. Got it snug with a few nuts and then decided the best place to go from there would be mounting the intercooler.




I never really test fit the IC. I just made a mock one out of some cardboard and held it up to the car and said, "This should work." Well it worked...but barely. I'll have to get more pics of the clearance later on. For one thing its a tight squeeze to the pulleys, but the worst part is its width. When we were done it cleared by about a centimeter. One thing I knew would have to get cut out was this support thingy here...



After that was finally all figured out, we had to decide how to route the IC piping. I always envisioned the piping in my head the way we eventually did it. Our reasoning was because when I go with a custom tubular manifold and bigger turbo it will be over by the fender more. IC piping over there wouldn't work for the future so well over there. The way it is now, its fairly flexible for future upgrades.

Next was cutting the IC piping and debating whether to use the Hargetts or not. We decided not to use them yet because everything will probably change a bit when I get the intake manifold and also because I need to get some tight 3" aluminum 90's to replace the silicone ones we used (for lack of a better option at the time). That was one thing I didn't foresee.

Tacked the pipes up with the terribly functioning TIG and called it a night.



Next day we started out by getting the downpipe welded up. I need to put another v-band in it because right now I can't get it out of the car without having it on a lift. That will be for next time though. We did so many things right. Got it absolutely perfect as far as fitment is concerned. The downpipe used to hang a little low thanks to the first guy who made it for me. We chopped it up to accommodate the Holset and in the process sucked it up at least a few inches. My ground clearance has increased dramatically now. I'm super happy about that.

Notice the spark right next to my fuel filter!











and then we were finally able to use a friend's welder and got the IC pipes all buttoned up. They aren't the prettiest welds, but the penetration is perfect and they are strong ones. Next time we are going to grind them down and do some nice, pretty welds on it and fit the Hargetts.

Finally we had to mess a lot with the damned drain line because it required a 45 on the block to avoid hitting the alternator. We got it all sorted out though.

Like I said, I also moved the coils to the driver's side and changed up a few other things, but here is the finished product for the most part!



We then started it up (actually started it previous to getting the top pipe finished to check for leaks and it sounded awesome) and it was perfect. Different sound than the stock turbo for sure. Not sure how to describe it though. We then tuned the car for as low boost as possible and called it done.

I also noticed that the turbo spins down for a pretty long time after the car is shut off. Not like a BB turbo, but long nonetheless. Wastegate stinks up the inside of my car when it opens up because we didn't make a dump quite yet.

Anyway, I'm tired once again, so I'm going to have to call it quits. If anyone has any questions feel free to ask.

Oh, and all of the stock parts are for sale! Everything is in awesome condition. No cracks in the manifold or turbo housing, turbo made 20psi no problem, wastegate was perfect too, intercooler didn't leak, etc...everything is perfect. Let me know! It would sure be nice to recoup a little cash.

So the turbo is the stock k24/k26 exhaust housing w/ the holset compressor housing (holset hybrid)?

PS. very nice to see its almost all done. Now lets get you some Euro headlamps and one of my front grills :wink:

Looks freaking awesome Chris!!!!

WOOHHHOOO man looks good! Can't wait to see a video or two xD!