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monster turbo3 build
Topic Started: Jun 17 2011, 05:53 AM (36,547 Views)
t3ragtop
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Turbo3 and Twincam Tweaker

the waste gate on the kkk ko4 is set to open at 7 psi which will be my base boost for economy operation. i'm using a pwm boost controller with a target boost of 21 psi. a few guys in canada run 30 - 35 psi boost pressures and have done so for quite a while without engine failures.

i'm not doing a supercharger, mostly because i'm a turbo guy and partly because of the expense both in terms of cost and efficiency. parasitic drag from a blower doesn't make for economical operation. the turbocharging is largely a free capture of exhaust gas and doesn't rob the 3 banger of any power to operate it. also, with a tuning file massaged for economy, i can drop the boost and get the 50 mpg i was capable of with the stock turbo3 system (at around 100 hp.)

rtblwn over on teamswift built a supercharged g13. now he's building a turbocharged version. does that say anything? :hmm

i'm not worried about oil supply or the wet sump system. i've doubled the oil capacity of the system, incorporated an oil cooler, and i have run 18 pounds of boost on a pretty much stock turbo3 engine without hand grenading it. the 3 banger doesn't have any problems with loading the head up with oil aside from using the head gaskets that have a small return hole. i have an oil return hole as large as the pocket formed by the head and block.

i might be on the edge with my build but i am by no means blazing any trails. there are guys doing the megasquirt and high boost on turbo3 cars - my execution is just a little different. :)
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Deckers
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It looks great.

7 - 10 psi boost doesn't raise my eyebrows any. 25-30 would though.
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t3ragtop
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Turbo3 and Twincam Tweaker

sure, the turbo3 stocker runs a factory setting of 7 1/2 psi and it's very nice to drive. 10 psi started to wake it up, 12 psi made me want more, and 18 psi blew up several of the little ihi rhb32 turbos. it spun the turbine wheels right off them.

this turbo is a lot less fragile. the target boost of 21 psi is a limitation of the 2.5 bar map sensor on the megasquirt i built. i could get a 4 bar map sensor, run barometric correction, or some other stuff but i just happened to use the 2.5 bar map.

i'm still soldering wires out in some dreadful heat. it's almost too hot to be outside. :x
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t3ragtop
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Turbo3 and Twincam Tweaker

wiring and welding. i'll let pics do the talking.
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after por15 and heavy seam sealer.
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micro-pore sock on air filter. keeps water out nut lets air through.
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bogs
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Duct tape heals all wounds

That may well qualify as one of the best looking engine compartments I've ever seen :drool
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cris
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very nice work. but one thing i absolutely hate.... the muffler. i hope you dont plan on letting that giant fart can hang from the rear bumper for everyone to see. dont be one of those guys with fake 5+ inch muffler tips. at least make it a true 5 inch tip, not a visible tiny exhaust hole surrounded by a giant fake one.... better still hide the muffler and let a sensible size tailpipe do the talking.
Edited by cris, Jul 19 2011, 02:15 AM.
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z34-5speed
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Formerly "Tech Certified"

cris
Jul 19 2011, 02:08 AM
very nice work. but one thing i absolutely hate.... the muffler. i hope you dont plan on letting that giant fart can hang from the rear bumper for everyone to see. dont be one of those guys with fake 5+ inch muffler tips. at least make it a true 5 inch tip, not a visible tiny exhaust hole surrounded by a giant fake one.... better still hide the muffler and let a sensible size tailpipe do the talking.
Wow dude, a little rude are we? I'd recommend a slight change of attitude if you'd like to get along with everyone here.

The "tiny exhaust hole" is a silencer I believe, which of course has a function in the real world.

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cris
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you are confusing "getting along" with "24/7 unconditional ass kissing" .... there has to be room for honesty and constructive criticism among fellow metro owners. otherwise whats the point. it is my opinion that a giant muffler like that wont look clean on a metro. he can take my advice or ignore it. simple as that.
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Jezza
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Boost Junkie

Mine looks good ... so what are you saying Cris?? :lol
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t3ragtop
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Turbo3 and Twincam Tweaker

everyone likes what they like. it's okay with me if you share your opinion.

i've used the same polished stainless steel mufflers like those, bought from the same guy, on about 20 metros in 8 years. they have a nice tone, one let me get unrestricted 9000 rpm shifts on my twincam swapped vert, and i've never had one rust on me.

the pic shows the muffler as it came out of the box (not counting the hangers i welded on it) and i haven't pulled the baffle out of it yet. i'll run it with the 4" outlet as part of my exhaust design.

the turbocharged g10 isn't anywhere near as obnoxious and loud as a normally aspirated g10. the turbine blades chop up the exhaust gas and pull a lot of energy out of it so it has a way different note.

my final order of parts arrived today so i can finish the last section, up and over the rear suspension. i also got all my welding on the chassis finished up. here are some close up pics of the finished floor repairs.
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my fatmat floor insulation came today, too. i got the footwells and the area under the seats done. i'll try to finish the inner rockers and the rest of the floor behind the seats tomorrow night after i get back from a visit to 90metro.
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i'm anxious to get the carpet back into the car so i don't have to lay on hot, hard steel to finish the wiring inside the cabin. :P
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wizard93
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Very nice work on the 'vert. I can't wait to see the finished product. Some vids of it running would be nice, too.

Don't be put off by cris's feelings of fart-can inadequacy. Your car has every right to have one.
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t3ragtop
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Turbo3 and Twincam Tweaker

cris, after reading your post several times i don't get the "letting it hang off your bumper" comment.

as the muffler is twice as big as a stock muffler, and selected because it offers less than half the restriction of a stock muffler, it's a trick to stuff it in the same space.

i tucked it up as far as i could and it doesn't stick out at all, if anything it's shy of poking out by a inch.
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turbo charged engines respond very differently to exhaust designs compared to normally aspirated engines. the goal is to move gas out of the way as fast as possible, with the very least restriction, and that's why the pipe diameter is twice the size on my exhaust. also, the muffler construction is way different and it's not uncommon for mufflers to be represented as a "turbo" muffler when they aren't sufficient for turbo use.

having lived with my turbo3 vert for several years, i know exactly what to expect with this fart can. i ran the same muffler, from the same source, with a 2" pipe on my mostly stock turbo3 system. i've also run a 2.25" diameter exhaust with the same type muffler on a turbo3 and a pretty wild twincam with excellent results in tone and performance.

this is just in the way of explaining that i don't run these fart cans so much for looks as tuning results. also, because i build my own exhaust systems and i'm intimately acquainted with these cars i know first hand what it takes to wedge a true performance system into them. your position of using a "real" muffler with a "real" tailpipe isn't truly possible without engineering yourself into a corner (like losing the center jacking point in the rear or creating flow problems with tight, crushed bends in the pipe.)
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CityConnection
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Sir, yes sir!

Yup. My boosted GTi has a Magnaflow "turbo style" muffler with no baffles in it. Using a large canister style muffler is a great idea. Keep the baffle in when driving around town and you won't raise many eyebrows. Remove the baffle for track day and let her rip. Best of both worlds.
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Potter
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Col. Potter

i just....wait lemmie check....... yep i just messed my drawers.... both ends D:
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t3ragtop
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Turbo3 and Twincam Tweaker

red missile launch switch to the right of the steering wheel in the off position caps the boost at 7 psi, the cork in the fart cannon, and a .bin file in the megasquirt's brain tweaked for economy should get me the same 50 mpg i could milk out of the mostly stock turbo3.

flip the red switch, pull the cork, and load the performance .bin file from the supervisory netbook - look out! :drivin

i've been planning this for a long time so i really have considered many options. i needed several things from this car and i hope that it will turn out to be a good balance. i really enjoy driving a car so a "garage queen" was out of the question. i drive the car as a commuter during our roughly 7 month vert season so it had to be reliable (it always has been.) i want to hit cruise ins and weekend car shows with it so the car has to be presentable with the hood up (maybe a bit more than presentable, i want it to catch people's eye just like a prostreet car.) and, believe it or not, i needed to stay within a fairly small budget. spread out over a 20 month period, the project after parts sales was financially manageable (although there were more than a couple months that i was s-t-r-e-t-c-h-e-d.)

i'm on a first name basis with the counter guy at the local custom fastener supply house. smilin' johnny go an average of $20 a week for 20 months for stainless steel hardware and i'm still not done. :whistle

thunderstorms this evening kept me from working on the car and i missed 90metro when i dropped off potter's prize.
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