Turbo Build - Pics & How To Sections...Time to start!

[OceanStateTuning]

Okay guys I'll try and take some pictures in case someone else wants to go the same route I am to help with your Fabrication.

I took the Wife's 4G apart last night to do the Timing Belt (Mitsubishi recommends 60K services for some reason, It has 67k on it now) Anyway I went to change the plugs too while I was working on it and something has been bugging me to feed some boost into this thing for some time now so I ordered the 7 heat range plugs instead (Hopefully see those Friday).

The Basic build will consist of this for now:
PTE6262 Turbo
Tial MVS Wastegate
Crappy eGay FMIC
Mazda RX8 Injectors

I ordered the materials from RRE and Ace Stainless to make a nice Tubular manifold setup but trying to keep costs down / simplicity I think I came up with a good idea using OEM manifolds off a 3G to make this work (Time will tell). I had the wastegate, injectors, intercooler in my basement so they stand me nothing and I bought the turbo cheap off a guy that upgraded.

I got the E-S motor mounts on order, going outside to install the E-S Trailing arm and control arm bushings now. I will start posting some pictures up as soon as the flanges and 3G manifolds get here so hopefully by the weekend or next week the turbo will be mounted. I am probably going to go with a Turbo XS BOV or knock off of one, I used one on my Turbo CBR and my girl loved it, I think they are annoying but I can keep the exhaust quieter if I give her something else to make noise with. The wastegate will see a 4PSI spring, I am expecting some creep do to the size so we will see if I need to step it up to a MVR or something in the future but I doubt the RX8 420cc injectors will support much more.

Anyway I just wanted to let you guys know there will be a new build thread to keep an eye on, I am hoping one of the tuning program people get everything situated as I hope to have this on the road in the next 2-3 weeks tops. Back to work...

[tcsoccer09]

wow u must really love ur wife and trust her with that monster once ur through with it! gl with the build!

[OceanStateTuning]

Yeah well I shouldn't jump the gun the wedding date isn't till June 30th but I call her that so I don't forget when the time comes. But yeah I let her drive a car for me a little bit ago and she kinda has an itch for a turbo now...

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[OceanStateTuning]

Girl driving a Turbo Honda - YouTube

[tcsoccer09]

pfft honda...ur soon to b wife will lose more than her shoes when she floors her new build

[OceanStateTuning]

Originally Posted by tcsoccer09

pfft honda...ur soon to b wife will lose more than her shoes when she floors her new build

lmao, well she is gonna be forced to so some TIG welding when the tubing arrives, Looks like not till NEXT Friday for most of the hot side tubing. =/ Oh well I the plugs and stuff should be here tomorrow to finish up that crap.

To keep you guys happy here are some peaks...
The Turbo is a PTE 6262 Billet wheel:


Crappy small eBay FMIC I got for free:

[tcsoccer09]

looks solid all except for the coors...go bud

[OceanStateTuning]

Originally Posted by tcsoccer09

looks solid all except for the coors...go bud

I drank BL from like 15 till 21 or so they starting having stomach problems, coors light and I'm fine (26 now) but yes BL does have more flavor though Sam Adams seasonals are my brew of choice.

[OceanStateTuning]

Quick update, It doesn't look like my tubing will be here till this coming Thursday or Friday.

So I need to wait for that till I can do more of the turbo side.

I put the Energy Suspension motor mounts in, Front was easy, back wasn't fun.



I also put the Front control arm bushings in, they were pretty easy, Back trailing arm bushings suck to press in!

I put 7 heat range plugs in.



Injectors are in, I used RX8 Injectors as I had them laying around and are 420cc each, should be good enough for now.



You can see the RX8 injectors are a bit taller, by 10mm, so I had to space the fuel rail up, factory 4g spacers are 10mm so you need to run a 20mm spacer but I had a couple of 10mm spacers laying around so I just ran 2 on each bolt:



Also the Timing Belt was surprisingly one of the easiest ones I have done.

[mwaterous]

Glad to hear doing your rear roll stopper mount is no easier than it is on the GS. When I finished that, I still swore at the car twice more and glared at it for quite some time before I actually hopped in and turned it over.

[Animefreak1983]

Very interested in this project. Cannot wait to see how it turns out.

How did you get a free FMIC

[wgpengineering]

Originally Posted by mwaterous

Glad to hear doing your rear roll stopper mount is no easier than it is on the GS. When I finished that, I still swore at the car twice more and glared at it for quite some time before I actually hopped in and turned it over.

it took some crazy extension/uni-wiggle combos to get that aft mount off/on for me

at OP what are those other turbos you had sitting on the floor? i'm using an HX55 which is about the same size as a GT4202. trying to get a hx52 turbine housing/billet wheel

[OceanStateTuning]

Originally Posted by wgpengineering

it took some crazy extension/uni-wiggle combos to get that aft mount off/on for me

at OP what are those other turbos you had sitting on the floor? i'm using an HX55 which is about the same size as a GT4202. trying to get a hx52 turbine housing/billet wheel

There is a PTE 5857 there and a GT4088R, also got a GT35R and T76 in the garage for other projects

Yeah the rear mount would of killed me if I didn't have kick-ass snap on universal sockets.

[mwaterous]

Somebody loves his tools almost as much as his car. (metoo)

[wgpengineering]

Originally Posted by OceanStateTuning

There is a PTE 5857 there and a GT4088R, also got a GT35R and T76 in the garage for other projects

Yeah the rear mount would of killed me if I didn't have kick-ass snap on universal sockets.

so all 4 of those turbos are for other projects? well if you ever wanna get rid of the gt4088 or t76 hit me up...in the market for something of that size

[OceanStateTuning]

Originally Posted by wgpengineering

so all 4 of those turbos are for other projects? well if you ever wanna get rid of the gt4088 or t76 hit me up...in the market for something of that size

Yeah I like boost The GT4088R is like brand new with a high temp thermal coating on hot side and black wrinkle on cold side, was started a half dozen times to move it around, never even drove on the street with it but upgraded to a GT4294R, make me an offer if you know what the BB turbos are worth lol.

[OceanStateTuning]

Anyway I got the tubing in tonight so I got a few things done, Turbo is mounted in its final location, front 3 cylinders are connected, I just need to do the cross over pipe from the rear, maybe Sunday if I have time.
I took the pan down and welded a 10AN male fitting for the return - Man the RTV they use is strong!
Anyway I guess that's all I got done, spent a lot of time with the carbide cutter and the welder.

I think I took a picture or two with my phone, will check and post if so but I had a long day at work today and its midnight so I'm beat

[OceanStateTuning]

Okay I was debating on making a manifold or not anyway here is a sneak peak. I will be using two 3G rear manifolds (I got one free from a junk yard that shipped me the wrong part and looked like it would work so I bought a second)

Anyway here is how I will be using it:

[wgpengineering]

Originally Posted by OceanStateTuning

Yeah I like boost The GT4088R is like brand new with a high temp thermal coating on hot side and black wrinkle on cold side, was started a half dozen times to move it around, never even drove on the street with it but upgraded to a GT4294R, make me an offer if you know what the BB turbos are worth lol.

i would but i dont really have $1600 laying around...if i could just sell my laptop i would have close though...

[OceanStateTuning]

Originally Posted by wgpengineering

i would but i dont really have $1600 laying around...if i could just sell my laptop i would have close though...

Yeah, lowest I would let her go for is $1200, it is MINT though.

[wgpengineering]

...i wish i had known about this a week ago...i wouldnt have bought coilovers...i'll definitely let ya know though

[Animefreak1983]

If this works out for ya would you be willing to help me plan such a build?

[OceanStateTuning]

Originally Posted by Animefreak1983

If this works out for ya would you be willing to help me plan such a build?

I'll list everything used to make it work when done so you guys can replicate it, I'm just trying to find the simplest/cost effective way to do this for everyone.

[OceanStateTuning]

Oil Drain:



Rear manifold:



Front manifold to connect to rear:


Where the turbo sits:







So far to reproduce this you need 2" Short radius 90* bend, 2" long radius, foot of 2" pipe (I'm using Schedule 10 Stainless) an RRE 3G cat flange, Vibrant Performance T3 Flange and two 3G rear manifolds, 10AN Male weld on bung and a muffler bearing.

The wastegate I have is a Tial MVS, If you are gonna do this I recommend at least a MVR but I had this so I will give it a shot, Wastegate will be one of the last things I weld on as I want to make sure I have clearance for everything I need

I have 2 12" Pusher fans I am gonna install when I pull the bumper back off too do the charge pipe and BOV.

I got some Valentine Day party today that I am forced to go to, gonna try to get some work done on the crossover pipe before that though.

[OceanStateTuning]

V band welded on for crossover:





Doing some crossover mockup:





And then of course this has to happen =/





Anyway the V-band is made by Vibrant Performance, it is a 2" model as I am doing a 2" Crossover. The crossover is being made out of 16-Guage T304 Stainless. And yes it is going to be heat wrapped, anyone that has used Heat wrap knows how great it works - you can go beat the snot out of something, park it and grab the exhaust right after, so yeah it will be close to some hoses so it will get wrapped. I am a fan of the DEI stuff, Thermotec (cool it) makes good stuff also but stay away from the cheap stuff like promotive and any of the eBay stuff as it will not wrap that tight.

So looks like I might be at a mild stand still till this week when I can get some Argon =/

[nokiauser]

Good luck with your monster build!

[wgpengineering]

Originally Posted by OceanStateTuning

I got some Valentine Day party today that I am forced to go to, gonna try to get some work done on the crossover pipe before that though.

^better hope the wife/girlfriend doesnt see this lol^

this is a very similar setup to what i'm building except my turbo is going over where the battery was...its looking good though bro

[roman lujan]

Man from a tune up to a turbo build haha great work so far good luck with the build

[OceanStateTuning]

Originally Posted by wgpengineering

^better hope the wife/girlfriend doesnt see this lol^

this is a very similar setup to what i'm building except my turbo is going over where the battery was...its looking good though bro

Ha yeah.... I was gonna put the turbo more over the trans but didn't really like the way the oil return would of went so went this route

Originally Posted by roman lujan

Man from a tune up to a turbo build haha great work so far good luck with the build

Haha yeah the girl has been driving my civic and wants her car back...

[joeyb]

oh man! I love it. great job kyle - do keep it up. I love enthusiasm and extra, over the top effort. Not everyone has the means to do something like this - but I'm sure glad some of our members are doing so. I REALLY REALLY REALLY want to get mine done... it HURTS to be w/out my car.

[joeyb]

going to add this to the "Best Threads" index and other catalog/contents threads - is it ok if I modify your title man?

[OceanStateTuning]

Originally Posted by joeyb

going to add this to the "Best Threads" index and other catalog/contents threads - is it ok if I modify your title man?

Yeah awesome! Modify away!

[ptr149]

+rep for you man. I love what you are doing here, great find on the 3g manifolds.

[gspower]

those welds are crisp man, i can deff tell this isnt your first rodeo

[OceanStateTuning]

Originally Posted by joeyb

oh man! I love it. great job kyle - do keep it up. I love enthusiasm and extra, over the top effort. Not everyone has the means to do something like this - but I'm sure glad some of our members are doing so. I REALLY REALLY REALLY want to get mine done... it HURTS to be w/out my car.

Thanks, It amazes me how few people on here really mod their cars, hopefully this might give some people inspiration.

Originally Posted by ptr149

+rep for you man. I love what you are doing here, great find on the 3g manifolds.

Thanks! And they seem like they will work great, should be much easier for anyone to reproduce this using stock manifolds then going all custom.

Originally Posted by gspower

those welds are crisp man, i can deff tell this isn't your first rodeo

I've done a few custom things from turbo boats to turbo bikes, Sadly my heart is in building them and usually get bored when there is nothing left to mod, buttttttt this is the girls car so it will be sticking around for a while

[OceanStateTuning]

Here is my well update on nothing, I forgot to order 2 flanges for the 3G manifolds so I just sent RRE a e-mail, hopefully they will ship first thing in the morning to have here for the weekend, If the flange for the rear manifold crossover doesn't come in Friday then I am expecting the bends to do the exhaust on Friday anyway and I'll be able to finish up the Exhaust/Intercooler/BOV this weekend anyway. Stay tuned...

[OceanStateTuning]

I hate having to read something and not getting a picture, This is what her car looks like...

[Steveo]

This is great wis I lived back in mass still I'd pay you well to do this for me

[dejectedangle]

?? Love the idea of 3G manifolds!!! Do they bolt right up to the 6g75 I will be following this thread

Edit ur in RI I'll just need to see this in person when all done PLEASE

[OceanStateTuning]

Originally Posted by Steveo

This is great wis I lived back in mass still I'd pay you well to do this for me

Road trip haha

Originally Posted by dejectedangle

?? Love the idea of 3G manifolds!!! Do they bolt right up to the 6g75 I will be following this thread

Edit ur in RI I'll just need to see this in person when all done PLEASE

Yup they bolt right on, bolts & ports line up perfect. I bet you could use the cheaper 3G OBX headers on these cars if you modified the rear header and made a custom Y pipe, of course then you might as well just go with the long tubes.
Come by anytime you want, I'm with in walking distance from rt95 in Providence. I'm sure the wife will take it to some local shows though.

Was bored waiting for parts last night so I yanked the Fuel pump out as I had a couple old walbro pumps... I played with it for a bit and the design of the basket is way different then most baskets so modifying is a bad thing BUT I think I have a solution, Will post up my findings probably Thursday.




Kyle