Successful Day

[Seerlah]

Chrome extension to get photobucket pics to show up: https://chrome.google.com/webstore/d...alioapbifiaedg

Yesterday I tried to install the Tyrol Sport brake caliper sliding pin kid and it ended up a disaster. To put it short, I purchased a used replacement caliper and should be here shortly. Mike at Tyrol Sport was more than understanding, said he will replace the damaged brass bushing, and will install the kit for free. I am like a good 45min to an hour drive from his shop, but it's all good. At least I know they will get the job done correct.

But since my car will be on jack stands for the next couple days, figure I take this opportunity to install my turbo kit. Turbo kit is:
-Garrett T3 GT2871R .63 A/R (black 2000*F ceramic coated exhaust housing)
-PSi Concept T3 manifold (black 2000*F ceramic coated)
-ER Test Pipe for the PSi Concept T3 manifold
-Precision PW39 Wastegate.
-Turbo XS HPBC boost controller
-ATP fuel rail with ATP adapter to run stock like fpr
-Boost Factory SMIC (strictly for testing purposes with outlet changed to 2.5" and custom 2.5" aluminum throttle inlet fabbed. Greddy intercooler will be going in after testing is done)
-4 Siemen 630cc injectors flow matched
-Eurodyne OTS MAFless 630cc 93 octane tune ran at 3 bar fuel pressure
-TM Tuning AFPR
-2 VEI gauges (oil pressure, IAT, A/F, oil pressure)
-Innovate LC-1
-Mocal thermostatic oil cooler kit with braided SS lines
-not sure if I missed anything



I know my setup isn't nearly as fancy as other people's, but I have plans . Picked up 144x20 Brute connecting rods with AEB pistons, and they are going in when I do my TB in roughly 20k. Going to run this setup at 18psi, because that is where I feel comfortable. I know I can run more boost, but not really trying to chance it. Going to be on the stock clutch, as I'm rather broke. But picked up a Clutch Masters 228mm steel flywheel for cheap. Planning to use that with a CM 228 FX400 6 puck. That's my next thing to purchase. I have supporting mods, and blah blah blah. Anyways, onto pics.

Here is what she looked like last summer (I lowered the rear more, since then)


Today, I just did the vacuum delete along with SAI delete. Basically, prepping car for turbo kit.




Tomorrow, plan on placing on my 034 Street Density motor and tranny mounts (already rocking their snub mount with bracket). Along with that, draining fluids, take out turbo, manifold, lines, HFC, and replace thermostat (coolant temp does not like to always sit in the middle, and I changed my CTS couple weeks ago thinking that would fix it...nope!). Taking my time with it, but should have everything done by the next couple days. No big rush. Here is a pic of what is going in.



Edit: Cliff notes from the thread, unless you want to read it all

Pt. 1
-Been driving it daily on stock clutch
-Can not boost past 17psi without it slipping, so it is set at 17psi
-Picked up Clutch Masters FX400 6 puck with flywheel for a good price (used flywheel I had a local machine shop resurface, and brand new clutch kit from turbonerd/Martin)
-Tranny is on it's last leg, so holding out on placing clutch in till I get a new tranny
-Changed Forge 004 BOV for 001
-Made custom PCV dump out of -10 an black nylon braided hose and hose end fittings
-Innovate LC-1 took a dump on me, so replaced it with an AEM Uego
-Swapped in 2.0 Bosch TSI coils...no adapters
-T3 flange gasket keeps blowing out on me because I can not get the bolts to stop backing out. Seems I am the only one with this issue.
-Turbo Blew in less than 5k, sent it in to ATP for replacement under their Garrett Ball Bearing Replacement Program
-Currently waiting on new CHRA
-fixing any little crap, like rear coolant flange, while car is on downtime

finished product with the above setup



Pt. 2
-lowered compression forced me to place in my forge connecting rods with AEB pistons
-goofed on installing the rods by scratching the cylinder 4 bore that could not be honed out
-picked up spare block for $250
-did the rods on that, and spun a rod bearing on cylinder 4
-rod and crank ended up being trashed
-took crank from my old block and had it polished
-picked up spare rod that my tuner had laying around (same as the ones in my car)
-dismantled everything and went at it again
-worked out this time around
-car is running healty so far

pics from when I scratched the cylinder bore





mixed pics from 2nd and 3rd rebuild

-With the 3rd and final rebuild I did not cheap out with bearings and replaced all bearings. Basically a complete rebuild with hone and new piston rings.













Pt. 3
-decided to change my setup. went with an RAI plug and play setup





















Pt. 4
-T3 gasket blew and burned my ignition coil section of the engine harness, shorting it out
-replaced it with an auto harness and hard wired in a reverse light switch harness (made a DIY for this)
-went to turn car over after that and car would not start
-after chasing ghosts should have done the simple thing and checked compression
-zero compression on all 4 cylinders
-pulled front end off and there was plastic that got caught in the crank gear. it filled in between a couple teeth and my timing was off by a good 5 teeth. well, Mr. Obvious says I bent valves
-picked up a used cylinder head from an AZ member for cheap, but had no cams or CCT. no biggie. I would just swap those over
-head came in and started to go to work
-pulled old head and one intake valve on all cylinders were bent
-swapped out parts that were necessary
-all was good, but my T3 gasket still kept blowing
-finally took people's advice and had the flanges on my manifold and turbine housing milled
-been good so far with stage 8 locking bolts

[Seerlah]

Pt 5

-turbo manifold cracked (waiting for arrival of new one under warranty)
-poopie (Aaron) made me custom piping for the Treadstone TR18t and installed it for me. was able to keep all fog lights and bumper grills under the stock bumper. lots of trimming.
-swapped out Siemen 60 lbs injectors for Bosch EV14 60 lbs injectors
-waiting on my manifold to come in, place it on, and make it to Waterfest





Pt 6
-replacement manifold arrived, ceramic coated, free replacement from warranty. they made me a new one instead of fixing my old one
-was driving fine, went to WF, and turbo blew the next day after being home and me basically having some fun pulls
-picked up the Comp Turbo CTB 5152 (530hp) Triplex ball bearing unit with cast aluminum center housing
-the Garret Turbo and PSi Concept manifold was the root to all my problems. kept trying to fix something that did not want to be fixed. no issues since RAI manifold change and Garrett turbocharger change. even run an OEM Nissan T3 gasket that only blew once (blew for a reason I don't feel like explaining, but is explained in some post. but placed same gasket in after having flanges milled and it holds up like a mutant)
-upgraded to the Maestro Tuning Suite and a forum member is currently remote tuning my vehicle





Pt 7
-tranny blew, but it was inevitable. was bad from the day I bought the car and was only a matter of time. surprised it lasted this long. anyways, feels good having a tranny with no slop. haha. so, tranny swap was in order. also did the 4:1 center diff mod. did it to my old tranny, so just swapped over the entire housing with center diff inside.





Pt8
Realized I post a lot of negative stuff and never the good. Like my car is a non stop train wreck. haha. It was indeed a bumpy road, but car has treated me well for a while now (other than tranny blowing). Just had to earn my stripes. DD her most of the time, but have a different car I alternate between. Taking the B5 down to h2o next week. Hopefully Rich (Cgoon) can take some nice pics of my car for me. Pics will be added soon for Pt8!

[Spectre1130]

Dang, that looks great. How much did all that run you?

And what is it you said you were running for a tune? And how much did that cost you? I'm trying to find a flash tuner for cheap (relatively).

But again, that looks awesome.

[murdered APR a4]

Very nice can't wait to see it put together, haha I would stay at 15 psi lol just because I would be afraid of throwing a rod. But hope to see picture updates as this comes along Mitch

[biketsai]

Its about time!!!! Glad to see things are finally going.

Just curious, what mesh is that in the front bumper?

[AudiNFS]

So much awesome. Good luck on the exhaust manifold bolts, mine hurt (me) getting out. Can't wait for the results

[Seerlah]

Chris, that is LLtek Mesh sold with their bumpers. I was lucky to find someone selling it on ebay that he wasn't planning on placing on his bumper. Picked up 2 small sheets and one big sheet for $25+shipping. But LLtek will sell you the mesh for $88+shipping (they rape you, even though US does not charge border fees). I lost my driver's side grill, along with fog light. Bottomed out coming out of a club, and did not know till couple days later when I saw the grill missing...and my fog light broke at all 3 tabs with my intercooler shroud shredded to pieces (bumper also cracked at little divider at side grill to middle grill). Picked up Home Depot mesh to replace it, and have a replacement grill to do it again. I will need to redo the passenger's side also, because I need it to match the driver's side. But the middle one can stay just like that.

As for pricing, I am maybe ~$3,500-$4,000 into it. But the parts brand new can easily run you close to the $6000 range. I don't skimp out on my parts, but shop very thrifty. Just scoop up deals as they come along and know how to shop. For example, picked up my CM flywheel for $150 shipped (like $450 brand new). Also picked up my Brute rods with AEB pistons for $500 shipped (rods alone brand new cost $480). And my tune is a Eurodyne off the shelf tune. I'll pick up the Suite later, but not till after I upgrade my engine.

But thanks for the comments, guys. This has been a long time coming. Been piecing this kit for over a year, and finally got done with it last week when I picked up my tune. Oh, and I don't plan on taking off my bumper or front clip to install this .

[flynnr]

I am excited man. have you ever spent time in a bt a4? so much fun! one of my friends has an integra that is more hp than mine, but he spins the tires through 1st/2nd every time lol.

Its nice to take your time and not be rushed. My first turbo build was a 'shit i have to get this done over the weekend, or i will have to bum a ride to work' build. (I bummed rides to work that week lol)

Keep taking pictures, and videos when you get it up and running! What exhaust are you running after the DP?

[xdewaynex]

Nice to see you actually getting to do this now. Should be a nice fun ride once you get it together.

[SS92]

Are you running the 034 block breather adapter w/ your CC?

[Seerlah]

Sold the 034 catch can, and just going to run a dump underneath the car via heater hose. I am going to have a custom 3" downpipe made, and have a plan. I picked up the 034 block breather adapter that takes a 3/4" npt fitting. Going to just run SS -10 an line from a 3/4" npt to -10 an fitting to a t-fitting off the valve cover (have an AEB valve cover powder coated with a 1/2" npt tap). The t-fitting will have 1/2" male on one end, and -10 an male on the other ends. That t-fitting will have SS -10 an line going one to the block breather, and the other going to an exhaust dump. Picked up a -10 an check valve the other day, and that will be on the line between the t-fitting and downpipe. This will all be -10 an SS lines. Then on the exhaust, a Vibrant E-Scavenger. I think it will look extra clean and be functional all at the same time. This won't be done till a couple months though. My inspection is due in November, so I need to have an exhaust system with a cat converter installed. Found one that is 100 cell, so that's a plus.

And flynnr, never been in a BT car. Been around them many times, but never asked for a ride in one. I was actually just talking to my friend who was telling me about a person he knew with a souped up early 90s integra. No stickers, except for a bunch of z(s) on the side of the back windshield for sleeper status. Rather ansy at how the install for everything will go. Hardest part so far was taking out the damn SAI pump. It's like Audi didn't want you taking that thing out or something. Had to loosen the bracket, and was able to squeeze it out. Turbo outlet hose to charge pipe was already removed, so that made it easy. And I'll def take pics along the way. After what I have planned to get done tomorrow, should have my ready to just install my turbo (and everything associated with it, hardware wise), fueling, and ECU. My exhaust is currently a labree HFC to custom 2.5" downpipe to 2.75" resonated Milltek. When I have my custom downpipe made, going to have it mate to the 2.75" Milltek. But the ER test pipe I had them make in 3" and taper down to 2.5". So it will bottle neck a bit, but I'm sure I am not going to be pushing enough air to make it an issue.

Winston (Podi) also just set me up with a deal on one of his products he hasn't released yet, provided I take pics of the setup. Should be nice . He has a teaser thread on it, but I don't want to spill the beans. Nothing extravagant, but just cleans up something and makes it really easy to work with.

[Dan[FN]6262]

Finally!

2871 is a very fun turbo. You'll be fine running 20psi on stock block. Drop in the rods and crank it up to 30 lol.

[Turbwhistle]

I like were this is going!

[Seerlah]

Been broke and jobless. That's not my excuse, that's my reason. lol. But yeah, been a long time coming .

[CCA4]

Glad to see this coming along Mitch! I feel your pain, I'm piecing together a turbo setup now as well but will definitely need to do the clutch first.

[Seerlah]

My stock clutch has maybe 35k on it, so it should hold me over till I get FX400 money.

[biketsai]

If I were you, Id get into a BT car after your install. Not to have your ego broken, etc, but to see if your car is running right. I ran my PES setup for MONTHS without knowing there was an issue because I had never compared my car to another (late spool, bad WG).

[Seerlah]

But you were hitting full spool at like 5k rpm. lol. I think I'll notice something like that. But my mechanic constantly has BT cars come by his shop, and I'll ask one of them for a ride.

Also, what are your guy's opinion on Bosch FR5DTC plugs? I am currently running Bosch F6DTC plugs and they should be fine with my application. But I picked these plugs up also a while back, but never tried them out.

[flynnr]

Plugs are something that is very personal i feel. One person will love a set, and have no issues, while another person's setup ran like crap with them.

You might have to try a couple sets to find the one that works well with your setup.

If I were you, I would start out with what you have, but grab a set of bkr7e's and gap them at .028ish and go from there.

What are the dimensions of the garrett cored fmic?

ygpm

[Dan[FN]6262]

I liked them as much as I do my F5DP0Rs


the F5DP0Rs are the grand daddy of plugs lol.

[Seerlah]

Thanks Dan.

Flynnr, I am not a fan of NGK plugs. I really like the Bosch 3 prong because I don't need to guess if my gapping was done correct or not. Plus, my F6DTC plugs don't need changing till 25k. Not so sure about the FR5DTC plugs. I tried NGK plugs once, and really didn't like them. People seem to love them, though. And it's not a Garrett core, it's a Greddy. The core is 23.5x11x3. With end tanks is 29.25" long.

[melomandn]

Where did you get your Eurodyne software and how much was it if you dont mind me asking? Curious because I've been looking into that exact tune

[Turbwhistle]

Where did you get your Eurodyne software and how much was it if you dont mind me asking? Curious because I've been looking into that exact tune

Pag Parts in Queens/Long Island, NY.

[Seerlah]

Pricing for the Eurodyne tunes is listed on Pag Parts. I was also under the impression that there is no charge for upgrades. I was wrong. Also, Arnold does not want me discussing prices (upgrade prices). But brand new, the 630cc OTS BT tune is $600 (tune I have).

http://pagparts.com/index.php?cPath=103_104

Click the Buy now option, and it gives you more options (ie BT file).

[jaychen]

Good stuff buddy.

Looking forward to more updates!

[murdered APR a4]

Is that a forge wastegate actuator on your k03?

[Seerlah]

Yeah. Want to buy it? Turbo is toast, but the WG is good.

[viceprp]

Awesome! Finally this build go under the knife. Would be cool to see a dyno of pre/post rod upgrade.

[Turbwhistle]

Its would have been cool if you would have gotten dynoed to begin with as a base before you did anything turbo wise. Cant wait to see the results, been waiting to see your build for a while.

[viceprp]

If his turbo had problems then that won't do much for us to compare. Chip A4 is around 145-155whp.

[Turbwhistle]

Yea, i made 146awhp with chip, exhaust, and fmic. I was thinking of going to eurodyne this summer. I think it is would be better with the like extended package.

[Seerlah]

My turbo would boost 11psi on a 21psi tune. With the stock ECU back in, I still boost 11psi. But it takes longer to get there. But I do plan on hitting the dyno after I get my upgraded clutch. Heard those things put a beating on the drivetrain. My hopes is at least 250whp at 18psi. I think that is a reasonable hope.

[Turbwhistle]

So the stage 1 eurodyne tune is weak?

[Seerlah]

No. I was boosting 11psi because my turbo was calling it quits. When it was working, I used to boost 22psi happily all day long.

[andyrew]

My turbo would boost 11psi on a 21psi tune. With the stock ECU back in, I still boost 11psi. But it takes longer to get there. But I do plan on hitting the dyno after I get my upgraded clutch. Heard those things put a beating on the drivetrain. My hopes is at least 250whp at 18psi. I think that is a reasonable hope.

Oh you should be able to hit 250whp at 18psi.. I ran that much on a gt28rs

Build is looking great!!

[murdered APR a4]

Yeah. Want to buy it? Turbo is toast, but the WG is good.

Txt me or pm me with a price and we can discuss

[Turbo Nerd]

18-19 psi is enough, I ran that on my eliminator and pulled on stage 2 S4's.

[Seerlah]

Just coming in from taking a break. Got a headache (not enough sleep last night). Going to install 034 SD motor and tranny mounts when I go back outside, and that should be it for the day. Pics to come.

[dcampana]

Great to see the build start. you have been piling parts for a while now:)

love the pics of progress!

you have PM;)

[Seerlah]

Got everything I wanted to get done today:

-Drain fluids
-take out turbo
-take out old coolant and oil lines
-take out manifold
-take out downpipe
-replace thermostat
-install 034 SD motor mounts
-install 034 SD tranny mounts

Tomorrow I plan on making it an easy day

-install Mocal oil cooler
-tap compressor housing on turbo for boost pressure fitting and install fitting
-run my oil and coolant lines to block
-assemble ATP fuel rail with adapter, and test fit the 630cc injectors to IM with rail (I have new injector seats, but not sure if I want to install them or not. I don't have the hex bit, and it's like 20mm)
-place downpipe back in car (not bolted to midpipe)
-degrease engine bay
-put back together the intake side of the engine

But as for progress today, only ran into one issue. I snapped one of the bolts on the passenger's side transmission. When I was torquing it back down, I was not sure if I was fighting tension or not. Well I wasn't, and I snapped the head off. It's ok though, I'll have my mechanic fix that. Also, my coolant flange on the back of the cylinder head started to leak as soon as I removed the nut holding the oil feed to it. I did this last night, and woke up to a rather small puddle. It may be small, but it still exists. So going to just replace the o-ring on it, as I'm sure I just disturbed the balance and the flange is still fine. Oh yeah, my front bumper is still on my car

Everybody likes pics, so here are a couple.

Stock turbo has gone bye bye


Think I may have been running kind of lean. What you think?


Old Labree HFC with custom 2.5" downpipe


New ER Test Pipe with custom 2.5" downpipe. Wasn't even thinking about if it will fit or not going back in put together. Tried it before I went inside, and it doesn't. Going to take a apart and reassemble tomorrow where it needs to go.


And I think I found the reason to my transmission issue. Hopefully, transmission is still fine and this mount didn't f*ck it up. Won't know till I get my car started though. Looks at this OEM peice of sh*t.



And a trick I picked up today for changing out the thermostat. No need to unbolt the alternator. Just remove the positive cable (black wire) from the alternator (for top hex), and get a long 5mm hex extension.


And you can call me lazy...or whatever. Got the job done. lol


More pics to come, once she starts coming back together.