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Turbo Charged build thread...

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Stupid question time... the turbo inlet has some mesh over it - is that sufficient to filter all of its air? Does it not need something more than that? I'd expect you could still get bugs/small bits of leaf/sand etc. going through that?

Otherwise, still awesome!

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Stupid question time... the turbo inlet has some mesh over it - is that sufficient to filter all of its air? Does it not need something more than that? I'd expect you could still get bugs/small bits of leaf/sand etc. going through that?
Otherwise, still awesome!


Basically it’s the best of a bad situation, there’s just 2” of clearance from the mouth of the turbo to the back of the headlight, I will be getting something fabricated but it’s currently a work in progress, the mesh is just so I could get it up and running [emoji106]


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Been busy doing the miles, have checked head studs and all good [emoji106]
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Made a gauge holder, looks much better in real life, the pics make it look a bit s**tty [emoji23]
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It’s been a challenging few weeks, wet roads, snow roads, salted road etc have all hampered progress.

 

But finally upto 22psi, but it’s not been easy.

 

Have had wastegate issues, and a very hard to diagnose lean condition.

 

Wastegate now starts to open on a bench test at...

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After a number of smoke tests which none of flagged any issues, a high pressure smoke test finally found an issue

 

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The block off bungs I had installed had not sealed, so each time I was closing the throttle at high RPM un-metered air was being sucked in and causing the car to lean out and occasionally stall [emoji849]

 

Hope this is fixed now, but need some dry roads to fully test, at 22psi this thing will spin the tyres in 3rd gear pretty easily on a dry road [emoji12]

 

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Awesome job mate!! You going to let this sleeper loose at Santa Pod one day lol

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Awesome job mate!! You going to let this sleeper loose at Santa Pod one day lol


Yeah probably, my PB at Pod was in my Impreza 1/4 @ 12.80sec, would be cool to be that


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Still mapping, still fixing teething issues.

 

Boost keeps dropping off at high RPM, I’m battling 2 issues, high exhaust manifold pressure caused but the turbo being a tad too small, normally wouldn’t be an issue, but as the wastegate is so large the force applied on it is greater and is getting forced open.

 

So in an attempt to combat this I’ve had another exhaust system made.

 

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It’s not helped at all lol. So made a test rig up that clamps to the front of the Turbo to pressure test the entire intake system fully.

 

 

 

 

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At 10psi I had 4 leaks that didn’t show on any smoke tests I had performed. These have now all been fixed, just silly things like a clamp not being tight enough, a couple of bolts were letting air past through threads etc.

So now I’m currently back to wastegate spring selections and continued road testing and mapping. The end is hopefully in sight.




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Still mapping [emoji22] but the exhaust is now sounding superb



And gives me some noise level options


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So effectively you have made your own backbox delete with some insert pipes?

 I like it, asbo loud when you want and super quiet when you want.

You got the bottom of your troubles yet ? 

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So effectively you have made your own backbox delete with some insert pipes?
 I like it, asbo loud when you want and super quiet when you want.
You got the bottom of your troubles yet ? 


Kinda getting there :)


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There’s been a load of further updates, now running N55 coil packs.

Air filter has been installed and located in the bumper where the brake duct used to be.

Dump valve has been relocated hot side of the intercooler as was causing too much turbulence as it was too close to the MAF sensor.

IAT sensor has also been relocated as was suffering heat soak and not reading accurately.

All issues addressed, it’s been dropped off for final tuning. Updates to follow next week [emoji106]

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Well it’s back, and not all is great.

The HX35 Holset just can’t flow enough air through the exhaust turbine to keep up with the engine.

So for now it’s time to use the car for a while.

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These numbers do not tell the whole storey, the power curve was just ridiculous at 2bar peak boost, and as revs climb boost just dropped off.

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Boost has been turned down for now to a peak of 1.5bar dropping off to 1.2bar

A new Precision 6266 Turbo has been ordered and will be fitted at some point later this year, and then 600hp will be achievable with a superb power band.

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