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Yeah, I was reading about wastegates and what one dude wrote convinced me that an internal was better for me. I think he mainly referred to price, but it probably takes up less space as you mention.
Let's say I was to make my own exhaust manifold. What would I need? I'de probably need to first make a rather thick sheet of metal and get a pattern for the flat part that mates to the head, right? Then cut out all the stuff I don't need and file it down somewhat to make it pretty. Then I'de need the other plate that mates up to the turbocharger housing. I'de do the same there and cut out what I don't need. How think should this be? I see headers with ones a quarter of an inch or thicker. Is this necessary?
Then I'de need to take some pipe with bends in it and cut it apart and fit it so that it would make all four exhaust ports flow into one. Although if I were to use a turbocharger with that twin scroll housing then I'de need to think about making two exhuast ports flow into one twice. Then I'de need to weld it all together. Assuing I make the cuts very well so that there is practically no gap betwean the pipes, then during welding will the weld leak through the gap (no matter how small)?
I think this is how a shop would go about making one. Unless they took one pipe for each exhaust port and bent it with a mandrel machine to make perfect bends. Too bad I don't have access to one of those. That would be a pretty good way of making an exhuast manifold. The exhaust ports and the twin scroll housing ports are shaped differently though. The ends of the pipes would have to taper down until they assumed the shape of the ports to have really smooth and efficient flow. Maybe I'll make a picture to illustrate what I mean later?
Any thoughts, just rambling...
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I have a quick little question about this matter. You do realize that it would be much better and benificial to have internal and headwork done to the block right? So why not get that done first. You'll spend around $2000-2200 and get lots of power and a block strong enough to hold 40PSI.
2k2civic: Well, maybe not 40psi, but I get what you're saying. For me, custom stuff like that costs way more money than I will ever want to spend on my car. I'm going to DIY this baby all the way to save as much money as possible. I too will be taking care of other things first before actually bolting on the turbocharger. That step can wait.
Here's my list:
1. Install an oil cooler.
2. Install a transmition cooler.
3. Change the transmition oil.
4. Add some Red Line Water Wetter to the radiator mix.
5. Add guages. Oil pressure, fuel pressure, air/fuel ratio, boost pressure, and maybe even oil temperature.
6. Make custom guage surround.
7. Convert the LX cat into an EX-type cat. Meow? Extend the sensors. Buy or borrow an EX header for a while.
8. Finish off the rest of the exhaust system. Buy a pre-made cat-back, or go with custom 3" (thanx PerfectD3)?
9. Change out the head gasket with one that will resist blowout better. Copper?
10. Change out the fuel pump for one that flows more fuel. Might have to change the FPR too?
11. Make part of the intake piping for the turbo and top it off with a K&N filter. (finish the rest when the turbo is on)
Optional: Figure out the intercooler problem. Either water-to-air or air-to-air, don't know yet. Goes hand in hand with intake piping.
I think that's most of it. Did I miss anything? Then we've got the following:
12. Bolt on exhaust manifold, turbo, down pipe. (Remember gaskets for good seal and flexible exhaust piece for reduced vibration.)
13. Finish off the intake piping and put filter in a strategic location. (Remember that colder air is better.)
14. Add on the blow off valve to the intake piping.
15. Swap out the stock injectors for higher flow ones.
16. Swap the spark plugs for colder ones.
17. Take care of electronics to account for new parts. (Hardest of all and I still don't know how to do it.)
Optional: Bolt on the extra piping for the intercooler. Finish everything off.
Anyway, the first part of the setup is extensive, but important IMO. I might even add a new clutch before I get the turbo, although I guess I could just ride on the stock one for a while. I bet it would die fairly quickly though. Then there's the whole upgraded ignition thing. Maybe doing that before putting on the turbo would be a good thing too. Although you can ride with lower boost levels for a while and then upgrade the ignition later if you wanted to run higher boost levels. I probably will; boost junkie!
Now testing:
16. Dial the boost way down. Start off slowly.
17. Turn on the car and check for leaks in the intake piping and exhaust piping. (I don't know exactly what to do yet, but I'll read up on it.)
18. Check the exhuast fumes for signs of running rich or lean. Air/Fuel guage comes in handy at this point too!
19. Check all the guages.
20. Drive! Rinse and repeat.
How do you guys like my turbo DIY? [IMG]i/expressions/laugh2.gif[/IMG]
Not bad grey, but still missing several things. I don't know if you just quickly summed your plans up, or that is exactly everything you are going to do. I am still unsure if I want to go all motor or turbo. More than likely turbo, but I want ot have everything finalized before the turbo is even put in. God, where did I leave the map to my money tree at?
im trying to get a simple turbo kit going for you guys- something that will suit the needs for you beginers and something for the people that have internals done- all im trying to accomplish at theis point is to build aup a prototype turbo kit and hopefully put into production- most people that get turbos just run stock internals and are completely satisfied with the power, im trying to but together a kit that will work well for stock and scream with a built block- im not trying to build a world record breaker here- this is for you guys- this will be your kit- for your car- it WILL be OUR kit- dreams do come true- they just take a little work-
sincerley-
anthony miller
<< Not bad grey, but still missing several things. I don't know if you just quickly summed your plans up, or that is exactly everything you are going to do. >>
What am I missing? I just quickly snafu'de this together, so there might be a couple of things missing. See anything huge though?
Anything huge, nope. You got everything good. Now, we need to actually start getting some information and figure where everything will hook up (oil feed line...will we be able to find a plug, or have to drill into an oil galley(sp?)) and what will need to be moved and/or modified to get everything situated. Too bad we can't get closer pics of the HKS prototype vic so we can see where they ran this line or moved that thing, etc. Anyway we can take a picture and "zoom" in on certain aspects of it and still maintain a relatively good resolution?
since i dont feel like re-reading the previous 133 messages or whatever, what are the realistic hp/torque gains for this custom turbo kit for the EX... with the basic mods..? thanx !
