One of a kind 16g Turbo Build. FINSHED!

[Boostahaulic]

I have only posted here a handful of times since I've joined Club3G. However, for the last 6 months i have been vigorously mining information from Club3g and various other sites for information on how to turbo my car. And today i finished putting my turbo in.

For the record, im only 21 and just graduated out of college. This is my 2nd car and I have never attempted something like this before, so this was a HUGE learning experience for me. I found all the parts, paid for, and built everything myself, i had a few friends help me for some extra hands, which really helped speed things up.

I pieced together this whole kit over the course of 4 months and a couple friends helped me do all the work over the course of a couple weeks.

Parts list:
Small 16g Turbo (freshly rebuilt, waste gate welded shut)
38mm Turbonetics Evolution external wastegate (8psi spring)
Megan Evo 8 twin scroll turbo manifold
Custom 3" Stainless steel mandrel bent Turbo Back exhaust.
3" Cat, Blitz Spec R Muffler
Air conditioning removed
Wrx STI 565cc Fuel Injectors (sti pinks)
Evo 9 fuel rail, and fuel pressure regulator
Walbro 255Lph Fuel Pump
Stock Evo 8 intercooler Piping
Ebay Front Mount intercooler
Evo 8 turbo inlet pipe
40" -4an turbo Feed Line
10an Oil return
Ebay Recirculating Blow off valve (to be replaced)
AEM Wideband
Autometer 25psi Boost guage
Autometer Oil pressure guage
Stock Suck through MAF Sensor
ACT MB1-HDSS Clutch
NGK BKR7 Spark Plugs

All in all, i spent about $3,000 on turbo/replacement parts.

I'm sure i'm forgetting some things.

Before i started putting this turbo on i replaced all of the fluids in the car, replaced the timing belt, timing belt tensioners, water pump and i replaced all of the seals/Gaskets (stock head gasket)

Tuning:
I decided i wanted to learn how to tune, so im taking on all the tuning, i will be doing a street tune, ande eventually getting dyno time to get some numbers, and finish tuning,

I decided to use a modified Evo 8 rom, with plans for the Typhra mod in the near future.
Using ECU flash to tune
EvoScan to datalog.


This was the car before i started. Yes it needs lowered...


Engine bay before, I started to relocate some things.


Guages


Small 16gTurbo




I decided to do something different. Most people who run a 16G DSM turbo run into the problem of the downpipe being to close to the power steering pimp. And the Evo 16g turbo requires spacers and studs. Using the Evo 8 twin scroll manifold, and 16g dsm turbo i made an adapter that moved the turbo centered between the block and intercooler. All while keeping the turbo away from the Power steering pump. Also, with this adapter i'm able to use an external wastegate, no boost creep for this guy!




I pieced together this whole exhaust. Its all 3" T-304 Stainless Steel. All Mandrel Bends. 3" Cat. Blitz Spec R Muffler.






All of the parts ready to go on!


Installing fuel injectors!


Installing clutch!



All assembled










Im still working on the tune for this car. And i need to fix how the blowoff is hooked up. I don't like the way i had to do it. I'm almost finished with this build, and i'm VERY happy with the way it has turned out. No leaks, no problems as of now.

I will upload some videos as soon as i get a chance to.

Let me know what you guys think.

[Pale Horse]

Looks like it was a very clean, well thought out install. Nice work. Didn't see anything about the electronics being hooked up though. Make sure you keep an eye on your engine vitals, with paramount importance lended to your wideband.

As for tuning, good luck, the learning curve is quite steep, just make sure you start out with a suitable base ROM and work your way up.

All in all it gets two thumbs up

[Pale Horse]

Oh, and one other thing, you might want to go ahead and buy a bigger wastegate spring now so you have it when you're ready .

I was in your shoes over a year ago and said "12 PSI will be more than enough for me." Haha, that lasted about two weeks and I was craving more. The same will happen for you, especially on that small of a turbo.

[Boostahaulic]

Thank you, i have A LOT of wrench time on this car already, from fabricating/welding up the custom exhaust to installing all of the pieces, and even tuning the engine. It was a very fun project, and im kind of sad its over.... for now haha I already have plans to up the boost once i get the tuning down good.

As for electronics, all of the stock sensors were put back on, wideband has its own bung welded into the exhaust. And i have an Oil Pressure guage for safety. But i have been monitoring everything else with a tactrix cable and EvoScan. Im running an Evo rom on the stock ECU.

[Menace]

Looks great and nice job!!!

[grfft3r]

Awesome work. Not a lot of people here talk turbo and actually make things happen.

[Boost 44203]

Yea, very nice. Good luck tuning.

[jaloosk]

This is the way you make shit happen.

[XwP1ayawX]

Well my friend, it looks like you know your way around a welder

[01GtCRazyKid]

very nice build!

[Masta560]

Looks nice and well thought out, congrats. Good luck tuning

[Boostahaulic]

Thanks for the compliments everyone!

And i just added this to my original post. But i am only 21, and this is the first time i have ever attemped something like this. I paid for everything and did ALL of the work myself. This is a BIG achevement for me.

Ill try to have some videos up today!!

[Thrice0805]

Very very impressive. All of the work looks great and you should be really proud of yourself.

[CloudINC00]

Looks good man! Glad you did your research. Whats your final goal for this build? Just mild power and a learning experience?

[Boostahaulic]

Thanks everyone! Still running good!

And i'm not sure how far i want to take this project. For what i've invested so far i'm shooting for 300hp. Seems like a high bar that i can work up to, but still hopefully not break everything, or blow the motor/transmission. And that also gives me a lot of practice with tuning.

Down the road i would love to build a track car. I've had plans of swapping the EVO AWD in, or to swap an Evo head, and build the engine to handle some serious power, but then the transmission worries me. And its still wrong wheel drive. So i think ill just build it to around 300hp, put disk brakes in the back, and a set of coil overs and call it a day with this car. Its not worth the money and all the work i would have to put into it. And i REALLY want to build a roll cage. But this isn't the car for that either.

[Boost 44203]

I really like it! Keep in mind you could always use the Kia or Hyundai head instead of the Evo. Generally speaking if it has "Evo" stamped to it, it's way more expensive.

[XwP1ayawX]

300 is easy. Stock evo injectors can flow up to 365ish, and the 16g can def handle it.

[XwP1ayawX]

I would call it a day. Maybe put in an LSD. I was also considering the AWD swap, but I can just see headaches down the road with it, and it's an old car. I think my next build will be an IS300. I really want to play with a 2jz. You gotta know when to stop throwing money at a bad platform.

[GTmitsu]

Doesnt the wastegate limit exhaust flow where its located. Being at a 90* angle from the exhaust hausing I'd think its restricting flow.

[03Quicksilver3G]

Very clean build

[Boostahaulic]

Thanks for the comments guys!

Originally Posted by Boost 44203

I really like it! Keep in mind you could always use the Kia or Hyundai head instead of the Evo. Generally speaking if it has "Evo" stamped to it, it's way more expensive.

This is true, but im weary about throwing down big power with anything to do with Kia or Hyundai on it. I had a Hyundai Accent, and that thing was a piece of crap. And it doesnt look as good as the evo head

Originally Posted by XwP1ayawX

I would call it a day. Maybe put in an LSD. I was also considering the AWD swap, but I can just see headaches down the road with it, and it's an old car. I think my next build will be an IS300. I really want to play with a 2jz. You gotta know when to stop throwing money at a bad platform.

Thats what im thinking, i dont even know about putting LSD in it since that is $1000 this may be my 300hp daily driver, and i may get a 240sx or a new BRZ to build up for a race car. The 2jz is an AWESOME engine. But I always wanted to swap the Rb25 into a 240sx.

Originally Posted by GTmitsu

Doesnt the wastegate limit exhaust flow where its located. Being at a 90* angle from the exhaust hausing I'd think its restricting flow.

It may or may not be, i can hit full boost around 2500rpm with this turbo. And it doesnt budge from 7psi (wastegate spring) once it hits full boost. If you look at a bunch of manifolds with an external wastegate it usually comes 90* off of the manifold. Unless its like a full race manifold. So i think if it is restricting flow, its very negligible. Reguardless, its still way better than the internal wastegate.

[Silvertune]

You realize that the Kia/Hyundai head of reference IS mitsubishi. Back in the late 90's early 2000's Hyundai bought most of their engines from Mitsubishi, the 4g63 being one of them. The internals are different but the head geometry is the same and lets you use Evo aftermarket parts which you'd want to use for the upgrade anyway.

[chavezeclipse]

the head itself looks the same, if you are worried about looks buy an evo valve cover on evom and throw it on the hyundai/kia head.

[XwP1ayawX]

Evo vc doesn't fit Hyundai head

[Boostahaulic]

Originally Posted by Silvertune

You realize that the Kia/Hyundai head of reference IS mitsubishi. Back in the late 90's early 2000's Hyundai bought most of their engines from Mitsubishi, the 4g63 being one of them. The internals are different but the head geometry is the same and lets you use Evo aftermarket parts which you'd want to use for the upgrade anyway.

I did not know that, thanks for the info.

I still don't know if it would be worth it. I think ill just stop at 300hp and maybe look into a better platform. If i tear the head off for DOHC i'm going to pull the engine and do the bottom end.. I wan't a better platform to work with before i spend that kind of money.

And if anybody has an questions on how i did anything feel free to ask. I have a bunch of pictures of this build. I just didn't want to upload all of them.