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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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ok- droped the car off today- first step complete- 2nd step talk to the welder to get the ball rolling will find out in a few days

 
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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.

 
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2k2 - My sentiments, EXACTLY!

My plans are to first build up the fuel system, the block, then putting the turbo in and all related components.

 
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that sounds like an awesome plan. it may take longer and more money in the long run, but your car is going to be hella fast if you do it that way.

 
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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]

 
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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?

 
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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

 
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YOu want to mass produce a turbo kit for our Civics, damn, you must have some serious moola.

 
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<< 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?

pinkytoe: Yep yep, we know...

 
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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?

 
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perfect- thats what were going to be figuring out as soon as we get to taht point-

 
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So how long will it take until the whole project is done?

 
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im figuring a month or so- hopefully- ill let you know

 
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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 !

 
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hopefully bettween 225 and 250

 
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well when i see the charts and the turbo has been built and does have those results... im down for one for sure. hehe

 
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ok im talking with josh- pricing out all the parts nessacary to do the kit- and labor- also looking into a custom dual stage wet nos kit ill keep ya posted-

 
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All this on stock internals?!?!?!?!?!?!?!?!?!?!?!?!?!?

I don't recommend any of that without at least sleeving the block. .

You'll probably end up blowing your engine into little peices with pistons flying out the side of your block. But hey, your engine.

 
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2k2Civic- Been saying this all along!

 
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Hey,

I would only be interested in a custom turbo once my warranty runs out, or for that matter even if a brand name company put out a turbo. Too unreliable at this stage to take that risk in blowing up my car.

Ray - Hopefully by 2005 there will be a Turbo for our car.

 
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post ur aol screenname,

 
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hell yea im interested!!! DOnt got the cash now but will by the summer. Keep us informed

 
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This sounds cool and all, but I would do the internals first. Check out the post in Products and Parts called GUDE BIG HP INFO. That would give you around 180 HP of all motor. Then with the turbo your car would be a land rocket.

 
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The Gude package is setup for NA. It raises your compression, among other things. I have already called and talked to them, and yes it is ok to use it, just wouldn't be a very wise choice.

 
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listen to what perfectd3 says. he is like a turbo god

 
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well sorry to let you guys down- priced out what it was looking like with labor and everything- looking at like 6g's- im not up for that- im gonna run nos- custom wet kit- sorry to let all you guys down but i got car shows to go to and crap to do- i can have my car be held up for like 3 months to set everyhting up- this should be done by the end of the week ill let ya guys know whats going on with it laters- sorry to let you guys down- nos in the short term will be just as much if not more hp than a turbo running like 6-10psi on stock internals- when a kit comes out ill use the nos for a spool kit- once again im sorry but funds are limited and im trying to get sponsored this year so ill let you guys know how this goes- cya
tony

 
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[IMG]i/expressions/laugh2.gif[/IMG][IMG]i/expressions/laugh2.gif[/IMG][IMG]i/expressions/laugh2.gif[/IMG]

Well, can I get that manifold you said you already got then? 3 months, you got an one armed monkey working on your car? What was your manifold setup to hold? A T3/T4? LOL! Let me know about that manifold!