turbo project
HOMEMADE TURBOCHARGE PROJECT
BY VASIN DOUGLAS
07/14/04:
I can start here, but this is not the beginning. As Steve Martin said, ?I was born a poor black child (LOL) Watching all my richer friends with their powerful cars made me envious. Horsepower was something for the rich, or at least richer than me (punk asses). What to do, what to do? I figured I could make cars fast if I knew how to fab and make parts. Although I have had many cars and 2 motorcycles,
this particular project started about 3 years ago when I made the turbo manifold. Progress stopped and now here I am again.
First thing I have to do now is to make a down pipe for the TDO5. This will be difficult because I have to do everything on a tight budget. All of my money was spent on tricking out the 16valve head. Never ever ever ever build a 1.6 liter NA engine. No matter what it won?t have much torque. Force feed the bad boy.
Things I must do:
-With my welding skills rusty, I have to freshen them back up.
-I need to get some parts for plumbing the oil and the water to the turbo.
-Build an exhaust system with, cat and flex pipe
-New motor mounts or do urethane filled mounts. The latter seeming to be the cheapest and the best performance idea
The car is a great handler, with TRD springs and KYB R2 struts, it?s a blast to auto x and drive on the stree.
Now it needs more power. Gtech says it has115hp. I have found Gtech to be accurate compare to chassis dynos. Although the hp number sounds lowthis is good for the NA 4age engine in this thing. The 4age has a very narrow power band. Max power from my engine is up near the 7,800rpm redline.
If I can increase the power by 50% this will give me 170hp to the front wheels. This number is not high and should be easily done and make me happy for about a day. But with my tight budget, I am poor remember, I will have to fuel the engine with a rising-rate fuel pressure regulator of an addition injector setup. This is not the best way to do things, but I have to compromise. In the future, as money comes (if there is such a time), I can go to an SDS total engine control.
07/24/04
Looking for a place to mount the intercooler on the FX16 is a real problem. There is not much extra space any where in this front end.
I sent the down pipe flange to be cut by my buddy Mike. I should get it back next week., then I can build the down pipe.
07/25/04
I have decided to mount the intercooler behind the front bumper. This will take a bit of modification to the bumper. I will have to cut out the center portion, so that the intercooler will fit. He intercooler will basically be inside the bumper. I will have to do a diagram to explain this
8/2/04
Well, I made pretty good progress. I have made the mounts for the intercooler. I did not think I would get this thing to fit. I know the bumper will have to be modified, but I am happy I was able to do a front-mount intercooler instead of the above the engine like on the 4agze.
Since I wanted to keep as many original parts under the hood as possible, I had to mount the turbo some what high. I will have to put a 2 inch-bulge in the hood to clear the turbo.
The next thing will be the intake plumbing and the down pipe.
As this project comes together, I see there will be adjustments that need to be made. Example: I am not sure the radiator fan will fit. I may have to use smaller or flatter unit.
8/15/04
Things that I have done in the update:
-Radiator fits
-Compressor to intercooler tubing tacked up
-Down pipe tacked up
-Starting to adapt the wastegate actuator so that it can operated from the opposite side of the wastegate.
8/29/04
I will take the coolant from the heater hose that comes off the block. This should prove to be the simplest place to do this. All I will need is a brass fitting that goes from the hose out of the block to the turbo and then a hose from the turbo to the to a fitting that will continue to the heater connection.
After thinking about this some more. I will have to have the water come from the heater supply and then have the water go back into the system where the water comes from after the heater core. Now I must figure which way the water flows. I assume it flows through the heater valve first.
08/30/04
I have ordered the urethane from: http://www.mcmaster.com/
Also, I have ordered a flexible exhaust section from: http://www.jcwhitney.com
I am going to see if I can get some tubing to make the water connections work. Home Deport has heater hose and fittings. I will start there and work my way to the sorry auto stores we have here in Austin.
For the Oil supply I will go to Austin Performance. Those guys know their stuff. I will pay a bit more, but it will be right the first time, and I can walk out with what I needed in hand.
I must also get a bottle of Argon, aluminum filler wire and stainless steel filler wire.
The aluminum wire is to re position the outlet of the intercooler and the stainless is to mount the flex coupler to the mild steel tubing
10/02/04
The water connections are rewelded into position.
Now that I have the addition fuel injector computer I should be able to pick up the pace. \
I have completed tacking up the exhaust system. Now I must weld it up. I have already welded up the exhaust from cat back.
I had taken some time off from the car to start a carbon fiber air box for my Weber DCOE?s. I will post some pictures of that soon.
3/22/05
I have not updated in a long time.
The car is almost finished, but the little things are holding me back. I did away with the intercooler for now. That can be an upgrade later. I needed to simplify things in order to complete things quicker.
5/02/05
I have not updated in a ?while. But I am selling my old school Celica stuff.
Here is the turbo support bracket. It allows expansion and contraction and will supporting the weight of the turbo. This should help the header live longer.
5/27/05
Well as anyone might know, when you're doing an automotive project. Especially one from scratch, like my turbo system, very few things go smoothly. So, why should this be any different?
THE CAR IS TOTALLY TOGETHER - except for the body work.
I went to start it last week and no go. I found that no fuel was getting to the engine. After figuring out the problem it led me to the fuel pump. When I put the car up for the project TWO YEARS AGO! It was in great shape. Now the fuel pump is screwed.
5/30/05
I took the pump pump out. This is no normal car. The Fx16 is all about fitting the most stuff and people in the smallest space (It has seating for five.), the fuel tank is under the passenger seat. Soooo, I had to drop the tank to get to the pump. PITA!
Once the pump was out, it looked as though it came from the anus of an elephant. The moral of the story: Don't leave your car with less than a full tank of gas for more than a few weeks. I even had fuel stabilizer in the tank. The pump was corroded and grimmy.
Good thing I got the spare pump from a Toyota 5mge. More flow and it is in better shape.
I got fuel pressure. Now I must fix the leaks.
6/05/05
IT's running!
Now I must tune it since it is not running smoothly. Plus I have an oil leak at the engine to turbo oil feed line. Sounds cool though, like a supercharger. Also the boost/vac gauge isn't working. So there is lots to do still be fore this is on the road.
6/19/05
Car's body work is back on. I tried to fix a oil leak and converted the leak to a fountain of oil. Went to the hydraulic shop and had them make a 5000psi 500 degree hose and fitting. Should feed the turbo well.
Turbo support.
Great prices on hotrod 22r, 20r, Ra24 and Ra42 parts:
http://www.oocities.org/vazfx16/
CelicaGarageSale.html
2. Throwout Bearing
3. Urethane motor mounts
4. Remove broken bolt from the transaxle PITA
5. Ported polish head
6. SS valves/Ferrea
7. TRD valve springs
8. CC's combustion camber
9. Mazda 626 AFM (25% bigger)
10. Compression lowered/enlarged combustion chamber
11. Mitsu td05 turbo
12. All plumbing custom
13. Custom straight flow/center-exit exhaiust system
14. Turbo Group Micro Fueler (Miller Woods)
15. Dual additional injectors
16. Custom TIG welded hheader
Vazfx16@yahoo.com
