Finally running again!
Thread Starter
7th Gen Photographer
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Joined: Mar 2004
Posts: 951
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From: Atlantic City, NJ
Rep Power: 280 
Finally running again!
After a 29 day turbo build that started Nov. 18 and ended Dec. 9 - I finally have a car that drives. May I first say that I've never done a DIY of this magnitude, and the complications I ran into taught me a lot about mechanics. My front end collision from back in 2003 was never repaired properly and my radiator support is WAY too close to my engine, making the room for this turbo NONEXISTENT. The turbo actually touches the rad support, as well as the lower charge pipe is wedged between my support and the front engine mount.
Many mistakes and whoopsies later that almost cost me a motor - it worked for 2 days @ 6lbs. of boost. Monday afternoon I blew out the gasket between my manifold and wastegate. It turns out my friend is an idiot and thought putting some 700º max RTV on the manifold-side of the gasket would help. I guess he didn't think he should ask me before doing something like that. Turns out it boils and then allows exhaust gas to easily pass out of the flange, rather than pushing against my wastegate like it's supposed to. So tomorrow evening I have to gingerly drive the car into the Honda dealer service dept. I work for as a service writer, and get my tech to help me replace that gasket (the ENTIRE assembly needs to be removed because of lack of space to work).
When my car heated up and ran for the first time we stood there marvelling at the engine bay and noticed my manifold paint was boiling. I said it would settle down because it's instructions said it needed to be baked once - which it had not been so far. However, a different idiot friend of mine thought he should check the paint's integrity by dragging a combination wrench along one runner... promptly tearing all the paint off that runner. Even if it's ugly, it works so I'll try and not complain too much.
And lastly - If anyone remembers from the FI&S forum, I couldn't start my car for like 4 days. A THIRD idiot friend of mine had removed (to check something under it) then only hand-tightened a ground, thinking that was enough. I never checked it because I never knew he took it off. After 4 days of troubleshooting every FRIGGIN' fuse and relay, I finally tried checking that ground. Yup. Car fired right up.
So... no pictures yet as it doesn't work (technically) but once I get it running well, I will wash it and post some pictures. Once I'm sure it functions for another week or so without any more problems, the dial is getting turned to 8 lbs.
For all three of these mistakes, I have to credit my friends with most of the build. They VOLUNTEERED more than one friday night without sleep, working out in the cold in my driveway. One guy did this FOUR TIMES. Everybody makes dumbass mistakes - but the loyalty to a cause to spend all that time for free is amazing.
Anyway - more updates to come.
Many mistakes and whoopsies later that almost cost me a motor - it worked for 2 days @ 6lbs. of boost. Monday afternoon I blew out the gasket between my manifold and wastegate. It turns out my friend is an idiot and thought putting some 700º max RTV on the manifold-side of the gasket would help. I guess he didn't think he should ask me before doing something like that. Turns out it boils and then allows exhaust gas to easily pass out of the flange, rather than pushing against my wastegate like it's supposed to. So tomorrow evening I have to gingerly drive the car into the Honda dealer service dept. I work for as a service writer, and get my tech to help me replace that gasket (the ENTIRE assembly needs to be removed because of lack of space to work).
When my car heated up and ran for the first time we stood there marvelling at the engine bay and noticed my manifold paint was boiling. I said it would settle down because it's instructions said it needed to be baked once - which it had not been so far. However, a different idiot friend of mine thought he should check the paint's integrity by dragging a combination wrench along one runner... promptly tearing all the paint off that runner. Even if it's ugly, it works so I'll try and not complain too much.
And lastly - If anyone remembers from the FI&S forum, I couldn't start my car for like 4 days. A THIRD idiot friend of mine had removed (to check something under it) then only hand-tightened a ground, thinking that was enough. I never checked it because I never knew he took it off. After 4 days of troubleshooting every FRIGGIN' fuse and relay, I finally tried checking that ground. Yup. Car fired right up.
So... no pictures yet as it doesn't work (technically) but once I get it running well, I will wash it and post some pictures. Once I'm sure it functions for another week or so without any more problems, the dial is getting turned to 8 lbs.
For all three of these mistakes, I have to credit my friends with most of the build. They VOLUNTEERED more than one friday night without sleep, working out in the cold in my driveway. One guy did this FOUR TIMES. Everybody makes dumbass mistakes - but the loyalty to a cause to spend all that time for free is amazing.
Anyway - more updates to come.
Joined: Oct 2002
Posts: 4,248
Likes: 2
From: Rockville, Maryland
Rep Power: 331 i remember my turbo install back in march... it took 3 of us about 6 hours to finish the job, including fabbing a down pipe. crazy fun though, spending that much time with some good friends and working on the same thing for that long makes for a very funny experience.
) 
Joined: Mar 2003
Posts: 2,351
Likes: 0
From: Houma, Louisiana
Rep Power: 305 I can totally relate to your situation. Upon removing the alternator to ease the install, I snapped the post on the alternator. I though sure I could just back it out and replace with a new one. NOPE! Had to order a new alternator from Autozone, took 2 friggin weeks. Dowtime FTL especially when its your only car.
There is gl@ss in my @SS...
Registered!!
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Joined: Jun 2006
Posts: 1,453
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From: Chattanooga, TN
Rep Power: 256 ive got a buddy who doesnt know anything about cars except how to drive one, but hes there every time i need to work on mine. i get the beer and pizza and hes there to get wreches if youre under the car, wash the windows, whatever. even if they dont do much you still have someone around to bs with
Thread Starter
7th Gen Photographer
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Joined: Mar 2004
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From: Atlantic City, NJ
Rep Power: 280 Click the link in my sig about Automotive photography. I used alot of pics of my own car as examples for the first section, which I wrote.
Registered!!
Joined: May 2005
Posts: 617
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Rep Power: 262 I got a question... what kind of computer / fuel system are you running? I was reading your other turbo posts, it sounds like you just bolted on & went. Did you use the emanage? I thought you would need a tune first in order to run?
Joined: Jun 2003
Posts: 2,161
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From: Macon GA
Rep Power: 300 i can tottally relate, took about a few days to install my turbo - then sat at a shop for a month. it took an additional 3 weeks when i did the head gasket by myself.
Thread Starter
7th Gen Photographer
iTrader: (2)
Joined: Mar 2004
Posts: 951
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From: Atlantic City, NJ
Rep Power: 280 LOL I'm washing it right now guys, DAMNIT! I am running the E-Manage with the map Hyaboosta emailed along with the kit when I bought it. It's tuned for 10psi and I'm currently running 6... so it runs rich as hell. I am too scared to run 10psi though. I don't have another car if I blow this one up, so I want to run 8 I think.
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