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Progress and a Sunburn...an ongoing build

40K views 336 replies 59 participants last post by  Ataru  
#1 · (Edited)
So, after 18 months of sitting in storage and untouched, I have been able to tinker here and there, but nothing serious until this weekend. Timing belt and cams got done Friday, but Today was the big work. The DP and intercooler piping.

This is how it sat almost 2 years ago with my old turbo kit on it...
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In storage disassembled(built engine installed and cleaning up engine bay...not that it did much good after sitting for 18 months... :
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This will be my 3rd Turbo 'setup' ive had on this car. I see something new and HAVE to make changes. The manifold, I'm sure you recognize, but I had to modify the DP some to fit my setup alittle...and the intercooler piping, run reverse from the 'typical' orientation. One step closer to completion. I hope to have it done in the next month or so and up to TS to tune. :) :party::evilgrin:

My inspiration/model: (slightly modified)
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First pic is my initial welding attempt using Flux-core wire and 'winging it'..not too big a deal because its going to be wrapped anyway...

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Pictures from todays work:

(note: Second time welding...had a buddy come and show me some basics..with gas, and the rest..trial by fire...and two burns to go with it...damn hot pipes...

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We put the MAF down low because it gave us the most straight piping before and after and i like it being tucked out of sight.

Making sure it fits with the headlight in:
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Hot side intercooler tucked inside the traction bars:
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Full view:
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And mach-up with bumper on:
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And yes, there is about 2 inches of clearance behind the headlight and about 1/2-3/4 inch on top between the hood.

Now, off to powdercoat and buy new couplers(that fit).

Next weekend:
Adding a 2nd muffler(magnaflow) to the exhaust and finishing the DP connection...

Still to come: (shooting for completion in 2 months)
-COP install
-Finish wire-tuck
-Traction bar install(completion)
-J&S install
-Inpro ST170s back on(have to clean up the lenses and reassemble)
-Custom Side mirrors remaking another set of the ones i use to have on(see 1st pic)
-Tuning (Topspeed)
 
#2 ·
The top of the wastegate looks like it might make contact with the slam panel when the engine comes off load and rocks forward a touch.

Certainly getting busy!

Keep it up...
 
#4 ·
The top of the wastegate looks like it might make contact with the slam panel when the engine comes off load and rocks forward a touch.

Certainly getting busy!

Keep it up...
That wont be a problem. I have a special treat waiting for me in NJ I have to pick up later this month that will create about another inch of space there. Plus, I have all VF mounts and an ingalls stiffy, so the engine really wont be moving, but i see your point.


Nice man. That's a man's turbo right there. Your welds got exponentially better on just the 2nd try, heh.

I say shoot for sooner than 2 months! J&S takes...15 min. COP won't really help much with power. Headlights are easy. Wire tuck probably takes time.

The best part is that you are so close to TS.
Yup, Ive kept the same turbo through all the kits...its the original t3/t04e that Econorocketzx3 used on his car back in the day when he was breaking new ground on a stock zetec turbo focus on the drag strip. I think he still ranks in the top 10 for drag times. His kit was my first 'real' kit...had an aerocharger on before that.

I say 2 months cuz that about how much longer I'll be in NC before I move again...:what: I'm rushing to get it done ASAP, believe me. I think the biggest chunk was done today.
 
#3 ·
Nice man. That's a man's turbo right there. Your welds got exponentially better on just the 2nd try, heh.

I say shoot for sooner than 2 months! J&S takes...15 min. COP won't really help much with power. Headlights are easy. Wire tuck probably takes time.

The best part is that you are so close to TS.
 
#5 ·
Awesome.

Just sayin, though...you could have the car tuned WELL before a lot of the other mods. Who needs headlights, COP, wire tuck, or mirrors when you're pushin 500 to the ground? :D
 
#6 ·
^^very true. well...COP i need...sold my coilpack and wires :)...but neverthe less, i see what you mean...Should be able to turn it over and see if it runs in the next week, so we'll have to see.
 
#7 ·
What's estimated completion of COP?

From my searching, it looks like econorocket ran a 13.38? I didn't see any faster times. That's nice and all but judging from the size of your turbo, you can hit 12s no prob.
 
#8 ·
What's estimated completion of COP?

From my searching, it looks like econorocket ran a 13.38? I didn't see any faster times. That's nice and all but judging from the size of your turbo, you can hit 12s no prob.
well, i can finish it now by soldering the wires to the coil, but i wanted to find the harness connector for a clean look. dealer wanted 18 bucks a piece for 4 of them.... so, off to the junk yard.... i might just end up soldering it, and add shrink wrap to make it look pretty.

Ive got almost everything done to this thing possible, minus a return fuel setup, so although ive only tracked the car one day(207hp, 14.7), i would sure like some impressive results...both hp and potential 1/4 times...(although the latter might take some time to get good at)
 
#10 ·
Ok, without return fuel, 400whp is the kinda safe limit. CFM made 454 with stock fuel system, big injectors, and KB BAP, but that's scary. Also, you would always have to have at least 3/4 tank of gas to make sure you didn't lean out. 400 will get you low 12s if you're decent and high 11s with practice. Jared estimates 420whp when he ran 11.4 so....
 
#11 ·
well honestly, although high hp would be cool for bragging rights, the fastest car i ever drove was a stock 2000? Z28 camaro(aside form my car when it was 207), so i would think by everyone elses statements, that 300-350 would be more then enough for me....but 400 would be nice too :)
 
#12 ·
300whp in a lightly stripped out ZX3 is brutal. Yours kinda looks full interior, though? Still fast.

400 allows you to run with the really big boys...like stock C6 vettes and the like. Camaros would become laughable. Mustangs wouldn't be worth your gas. Lightly modded Evos and STIs would also make you giggle as you toyed with them at 3/4 throttle.

400 is my ultimate goal. Sorry, just dreamin right now...
 
#46 ·
i can speak from plenty of experience of this.. 300 will let you play with alot more than c6 vettes... try c6 zo6 vettes.... sport bikes.. modded evos,stis, porsche 911 twin turbos... cobra mustangs... you name it.. and i have full interior, with a bumpin system.. and i have the Recaros which are way heavier than the stock cloth interior... i wallked a gxsr on my low setting which is 308whp and 312 wtq.. from a 60 roll.. just to say the least he was like hat the hell...lol... i have yet to have to use the 400whp setting...lol.. 400whp on a focus is actually kinda retaerded... now granted tq is where its at.. 412 wtq is just stupid anywhere especially the street.. i almost never use it.. once every 5-6months...lol.. its just flat out too fast..
 
#14 ·
Update:

Got the COP all wired up on the plate, now just need to splice it into the harness. Will have pics up in a little bit.

BTW, anyone know a good place to get quality fasteners from? bolts, studs, etc, that arent the 'cheap' home depot kind?
 
#21 ·
Update:

BTW, anyone know a good place to get quality fasteners from? bolts, studs, etc, that arent the 'cheap' home depot kind?

Fastenal. It is a store that litteraly carries anything. If u need/want it they should be able to get it. And their fasteners are super cheap compared to hardware stores.
 
#16 ·
well, anything that stiffens the motor will tranfer the vibration somewhere...and it happens to be the rest of the car. Honestly, I havent driven with the ingalls on the car yet. I got it shortly before pulling the old engine. From what I've read, with all 3 VF mounts, the engine sticks put and doesnt really go anywhere, but i have no first-hand experience.
 
#17 ·
Yeah get that. I just want to keep the car ultra street friendly, so looking for alternatives to stiff mounts.

Might do some research on the Ingalls and see what the word is.
 
#18 ·
The 3 VF mounts will hold the engine pretty dang solid. I prefer the Massive Unbreakable trans/torque mount, though. It's a freakin beast.

The Ingalls stiffy does not fit on the SVT without modification.
 
#19 ·
So, I didnt have any luck finding harness pigtails at the local junkyards, so I just said 'f it' and soldered the wires and used some shrink wrap. I think they look pretty clean (other then the fingerprints on the polished cover). Saved 80 bucks. (what the dealer and Jay racing wanted for the pigtails) Tomorrow I'll put it on the car, but for now, i tried to 'simulate' what it would look like with the wires hidden underneath...

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Thanks to bmylez's encouraging words, im shooting for getting it running by the end of next weekend. The visual stuff can wait...I wanna get this running and tuned, THEN go back and 'clean up' and make it pretty :)
 
#20 ·
That's a really clean install. Could have fooled me that it's not a plug-n-play harness!

Next weekend, shoot. I'm fixin to order my turbo tonight/tomorrow through Top Speed so it looks like it's a race to the finish for both of us!!!

En garde!
 
#22 ·
You wanna really make those wires scream? Cover them in PET nylon sleeving and then shrink the ends. (www.mcmaster.com)

Also, put the wires thru the plate with nice grommets - will give a great finishing touch. Screw factory look. Factory uses tape. This is a custom application.

Trust me.
 
#24 ·
You wanna really make those wires scream? Cover them in PET nylon sleeving and then shrink the ends. (www.mcmaster.com)

Also, put the wires thru the plate with nice grommets - will give a great finishing touch. Screw factory look. Factory uses tape. This is a custom application.

Trust me.

ooooooo pretty colors. I may just have to do that. I'll mark that down for the post-tuning 'prettification'.
 
#23 ·
lol.

You know if they do in-house turbo rebuilds? I could ask them , but it just popped in my head when you mentioned turbo...I may need mine done. its been sitting for 2 years, so I guess there is only really one way to find out.

You know whats crazy...I may be coming to Lackland AFB in the next few months for 4 weeks...I may be switching services and the schooling is there. 8 years Marine Corps is long enough. I may just have to drive out there instead of fly...:evilgrin:
 
#25 ·
Top Speed does not do in-house rebuilds. They do fabbing, engine building, and tuning.

So they don't make you do basic when switching, do they? AF basic compared to Marine basic would make you very bored. Not to mention it wouldn't make any sense for someone with 8 years service to be yelled at again, hah.

I agree you should drive.
 
#26 ·
So Im looking at the PET nylon braiding, and I just can't decide whether to go clean all-black, or blue accents, or _______.

What color should i go with? or combination? Now, I was thinking of using this to dress up any remaining visible wires, rubber hoses, visible vacuum lines...just about anything that would make it look cleaner.

http://www.cabletieguys.com/braidedsleeving/nylon-multifilament.htm

also, anyone know if the color fades with heat? )like those cheap colored wire looms??
 
#27 ·
So, I realized yesterday that a wire harness i need(O2 sensors, crank position sensor, blah blah) is up north in my other car(from teh move) so im alittle stuck...sooo....what to do with my time? ...

Wire tuck(with the wires i have). I read a write up here..well, a write-up in progress, but i had a much easier idea. i have it all prepped, just waiting for my nylon sleaving to come in (thanks for the idea Ray). I''ll post up some pics in the next few days when i get it finished. The only wires you SHOULD really see, if i do it right, are the ignition and fuel injector ones... :)
 
#28 ·
UPDATE:
Finally got to 90% finish my 'wire tuck' attempt and start assembling the big parts of the car. Ive got 2 weeks to finish it, break in the new headgasket (anyone know how many miles before boost?) and put the turbo back on and take it to Topspeed before I move back to PA. Gonna be busy.

Here are a few pics from what I finished today....for anyone that cares:)

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#117 ·
UPDATE:
Here are a few pics from what I finished today....for anyone that cares:)
]
I just stumbled upon your thread today.
What caught my eye was the reiger bumper/st170 lights/kalimari sides
But than I saw your turbo build & I thought I struck gold.:hump:
I came across Dominic's setup about 6 months ago & now to see your version being build is great .
I 'll be looking forward to you posts!:thumbup:
 
#30 ·
I figure head gasket break-in is the same as newly built motor break-in since it would have a new head gasket as well. 3 heat cycles, just letting it idle for 20 min then letting it cool allll the way down. Maybe drive it around town for a few miles, but after that, many agree you're good to go.
 
#32 ·
Gaskets do not require a break in period.

Nice job on the wiring :) In my opinion, nice wiring work should be shown, not hidden - but i know you're going for a different look. I'm also glad you went with black, it just really screams subtle perfection.