My ongoing project car

[N.RotaryTech]

Ok, continuing what my previous post says about this turbo set up, let me get the pictures & details rolling.

Some picture sets might not be clear of the progression of things, I was more concentrating on building this project, but I think you'll get it.

First the turbo setup I acquired.

(Post downpipe modification.)

I started modifying the down pipe cause it was too long as to fit in between my RB silencer and the turbo.



As i took off the RB silencer the studs got fubared.

I ended up shortening the totally stripped stud, and cut away a thread or two of the other stud, cause the fastener I used was hanging up.

This is what it looks like now.

I took it to a local car repair service center to get it welded together.
Added the extra O2 sensor bung later.

Future plan for this downpipe is to sand it down and cover it with hi-temp paint.

[N.RotaryTech]

Next, I fabricated the intercooler mounting.




I didn't even have to move the overflow tank or the horn. I did reroute the coolant tubing though.


I painted it black.

[N.RotaryTech]

Changing the fittings on the turbo.



This is what i used for the oil feed line for the turbo. Parts from the plumbing section at Lowes. They are for Faucets.


Here I fabricated some heat shielding for the turbo.

[N.RotaryTech]

Intercooler piping. I used exhaust tubing from o'reilly auto parts.


Painted.


I modified an intake pipe from a Subaru Impreza and used it for the intake pipe for the turbo. I cut a lot of things off of it to fit and used epoxy to fill the holes and seams.



I cut apart my old cone air filter to make a filter element for the MAF sensor. A normal size filter wouldn't fit in the engine bay.



I installed 750cc injectors in the secondary's and rewired the connectors from S5 to S4.


Parts, gaskets, etc.

[N.RotaryTech]

Kind of tight on the passenger side of the engine bay, but this is how things look.





I drilled a hole next to the radiator. Blitz BOV I traded some parts for. Used some clear tubing I had around instead of normal vac tubing which I didn't have.


The sun was killing this shot, but shows the IC piping.


The Subaru Impreza intake pipe installed.


I used an S4 turbo MAF sensor, changed the connector wiring, and have a piece of filter clamped on.


View from above the turbo. One of the heat shields, Oil and coolant lines installed. Also one of my attempts to fix an exhaust leak. I still have a leak.


Oil feed line and source.


Oil return.


Oil temp source via T fitting.

[N.RotaryTech]

The turbo is a Turbonetics T3/T4 series, I forgot the specs, I wrote them down someplace, have to find that.

It has an external wastegate that apparently came with a 10 pound spring in it.

720cc (not 750cc as I posted before) injectors in the secondarys, with 6 ohm resistors installed inline with the wiring to them, actually located next to the ECU under the carpet.

Stock Turbo AFM.

Stock TII intercooler.

Blitz BOV.

The engine is the same as I posted before. S4, 9.4 comp rotors, mild porting on the housings and end-plates.


And for the best part...

All this runs on the stock S5 NA ECU!


It will boost up to 10psi, but runs really lean up in that range.
Around 5psi AFR's are perfect though. 11's and 12's

Ive taken it for a drive / boosting just a handful of times.
But found out last night after a drive that my Nopi stage 2 carbon kevlar clutch filled the engine bay with burnt/slipped clutch smell.
So I might have to replace it after DGRR'11

I also found that the turbo's oil seals are bad, leaking through the exhaust and leaking externally.

So with all this, I'm expecting a possible clutch, turbo & engine rebuild after DGRR'11.