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 Old 05-24-2012, 07:36 PM   #1
 
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Default Navy's BT Build

Well i suppose its time to get this thread rollin. Only 3 more days left on deployment then a week of leave in June to get everything swapped in so its time to start orderin parts. Parts list is as follows:

BW s200- T3 T/S w/ 59mm comp wheel
Steedspeed top mount mani w/ 40mm w/g
AutoTech PF guts
Turbosmart 40mm w/g
PTP high press. relief valve
Grimspeed EBCS
SU intake spacer
Injector Seals
and...........
LTA intercooler setup. I plan on going blow thru with this setup as well similar to what Blue Streak was running. Hopefully i can get the maf not to spaz out with it on the cold pipe. Also gonna be getting atp's top mount hardware kit or whatever they call it along with some v-bands so i can re-do my exhaust set up since right now everything is welded up without any flanges and i need to re-do the Y junction at the rear axle. If i have time im gonna install the SURE rear diff mount while the exhaust is out. if not ill just get around to it. And also if i have time im gonna clean the valves while the mani is off since its been 67k without a catch can. I can only imagine what those are gonna look like...Only thing else i can think of is getting with DJ about setting up a base tune to get the damn thing started. I probably forgot a whole bunch of shit but im typing this at work and i have an excel file on my laptop with all the shit listed on that. Wish me luck!
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 Old 05-24-2012, 07:46 PM   #2
 
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nice, can't wait to see what the LTA with top mount will look like
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 Old 05-24-2012, 11:42 PM   #3
 
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Sounds sick nasty! Good luck with the build!
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 Old 05-24-2012, 11:46 PM   #4
 
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Sounds like some winning combos
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 Old 05-26-2012, 05:04 PM   #5
 
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Originally Posted by crazyp View Post
nice, can't wait to see what the LTA with top mount will look like
i plan on mounting the intercooler in the same area as bluestreak did. except the core im getting has the inlet on top of the cooler and the outlet coming out the bottom towards the side. kinda like an L shape. well a backwards L. only thing im concerned with is if the length of the cold pipe is gonna be enough for the maf to get an accurate reading.
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 Old 06-05-2012, 08:31 AM   #6
 
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So just got off the phone with Mike at SPS turbo. BTW, great guy, really helpful and knowlegable. Found out that the s200/300sx turbos need at least a 3/4" diameter drain line as per BW and im pretty sure our factory tube is only 5/8" and i imagine that diameter is kept when the return enters the block....gonna have to PM DJ and see what he did about this.
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 Old 06-05-2012, 11:35 AM   #7
 
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Well i pm'd DJ, and hes rocking a -10 (5/8") drain so thats what im gonna go with. Also where have you guys with DIY intercoolers get your silicone couplers from?
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 Old 06-05-2012, 05:28 PM   #8
 
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2.5" Intercooler Black piping kit 9pcs Free U Pipe | eBay
^ has most of the needed couplings, all others, like the one from the turbo to the intercooler piping are from siliconeintakes.com, you'll need a few extra straight couplings to connect piping as well, more than what is already in the kit, i think i needed 2 or 3 extra

I'm jealous of your top mount route, I wish I would've gone that way.
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 Old 06-05-2012, 05:43 PM   #9
 
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LTA should be a pretty interesting route. Should look nasty ... Definitely will be tracking this build. GLWB
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 Old 06-06-2012, 10:48 AM   #10
 
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You might want to check in with Steedspeed. I was originally going with a T4 TS topmount set up, but when i checked with them , they said they aren't making them anymore. I made the mistake of ordering the turbo with the t4 ts housing before ordering the mani
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 Old 06-10-2012, 01:58 PM   #11
 
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Yea i called steedspeed and they dont have the top mount t4 anymore so im gettin a t3 and the turbo from full race. gonna cost a bit more but thats no big deal
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 Old 06-10-2012, 02:08 PM   #12
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Originally Posted by Navy_Mech2 View Post
Well i pm'd DJ, and hes rocking a -10 (5/8") drain so thats what im gonna go with. Also where have you guys with DIY intercoolers get your silicone couplers from?
siliconeintakes.com

they'll likely have everything you need...even L2A stuff.

good luck with the build!
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 Old 06-11-2012, 09:09 AM   #13
 
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^ Thanks man. Seems like i keep hitting road blocks with this thing...kinda like veryone else lol
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 Old 06-12-2012, 11:10 AM   #14
 
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Ok little update here. I ordered the turbo, HPRV, fuel pump guts and crank case breather kit from PTP. I ended up getting the S259 rather than the 256. Its actually Erich's old turbo that he had before he switched to the S366. So now i just gotta get the intercooler and exhaust manifold and all my shit will be ordered!
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 Old 06-21-2012, 11:30 AM   #15
 
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Well guys ready for the big disappointment. Build is gettin pushed back till christmas. I didnt get my intercooler or my wastegate in time to finish the build. i got everything except for those 2 things in time. I had to drive to VA for my girlfriends birthday on tuesday and my intercooler didnt come till tuesday afternoon and im still waitin on the wastegate. But come spring, theres gonna be another big turbo mazda rollin around the jacksonville area!
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 Old 07-02-2012, 10:38 AM   #16
 
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Also might try out this EBCS instead of the grimm...

http://blogs.cobbtuning.com/2012/05/...trol-solenoid/
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 Old 08-04-2012, 11:06 AM   #17
 
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Little update: started getting blowout above 6k the other day...changed out my plugs since they were about a year old or so...blowout seems to be gone so thats good news. also gonna have my dad ship my relief valve, injector seals and crank case vent kit here so i can get those out of the way.

Bought a 309 piece tool set from sears the other day. they had it listed for 399 on the shelf but they hadnt stocked them yet and when the lady rang them up, they came out to 249! Winning!
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 Old 08-05-2012, 05:30 PM   #18
 
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Left front upper ball joint is toast. Fuck my life.
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 Old 08-09-2012, 11:33 PM   #19
 
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dude, good luck with your build.. seems like you are on the right path. vr os2 sw/aw haha
ill be by that area in mid november time. hopefully there is a meet so i can join in.
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 Old 08-13-2012, 12:00 PM   #20
 
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haha thanks man. if youre in town for the second saturday of november we have a meet called cars and coffee at the wild wing cafe off of southside blvd.

v/r,
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 Old 08-23-2012, 04:07 PM   #21
 
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Talk about torture...winter cant come soon enough.
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 Old 12-21-2012, 10:35 AM   #22
 
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Christmas came early! @djuosnteisn; thanks a lot man the line looks killer!

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 Old 12-24-2012, 01:57 PM   #23
 
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So since my brother is in town, and he works for beer, we changed out my front ball joints today.

Sorry about the cell phone pics... I've actually been putting off changine them for about 2 months now since I don't really drive the car much after I bought my truck. Anyway on to pucks of the carnage...
Left one

Right one

If you look at the visible edge of the socket you can see where its been egged out. And all the white/grey shit that looks like it doesn't belong is actually a mixture of sand and greese. A by-product of what happens when your dumb ass ex wife drives your car ON the beach. Took us just under 2 hours but we would have been done faster had the right control arm not gotten stuck to the bottom stud of the ball joint. Moral of the story, ball joints don't like sand.
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 Old 12-24-2012, 02:20 PM   #24
 
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Congrats man. What turbo is that? And are you going top mount?

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 Old 12-24-2012, 02:31 PM   #25
 
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Its a bullseye s259. and yes im going top mount. im actually gonna be installing it from the 1st to the 5th
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 Old 12-24-2012, 08:56 PM   #26
 
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Originally Posted by Navy_Mech2 View Post
Its a bullseye s259. and yes im going top mount. im actually gonna be installing it from the 1st to the 5th
Interesting...just out of curiosity, how come you chose that turbo in particular?

What will it net you over the standard go-to's?

When are you building the motor?
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Looking forward to see how this turns out.
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 Old 12-24-2012, 10:15 PM   #28
 
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Looks good man! Subb'd for results!!
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 Old 12-26-2012, 06:46 AM   #29
 
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Originally Posted by GunGuru727 View Post
Interesting...just out of curiosity, how come you chose that turbo in particular?

What will it net you over the standard go-to's?

When are you building the motor?

Motor build is gonna be down the line sometime. I just bought a truck to replace this as my DD so i have to wait for the funds to build back up.

I picked it because it was different, and because i got a sweet deal on it. I actually hadnt even heard of these turbos until i read DJ's build with his s300 and then later Erich's. This flows around what a 3076 does but is priced comparitivly less since its not a ball bearing turbo. Also being a journal bearing turbo, its rebuildable versus having to buy a whole new CHRA if something minor like a seal or a bearing starts to go out.
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 Old 01-02-2013, 01:43 PM   #30
 
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It has begunnnn!!!!!!1!1!11! (Insert appropriate mortal combat meme)



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 Old 01-02-2013, 07:37 PM   #31
 
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So end of day 1. Got all the stock BS out of the way and mocked up the manifold and the turbo to get some measurements for the down pipe and dump tube. Tomorrow I gotta get a couple bolts for the oil drain flange and track down some water fittings for the inter cooler and heat exchanger. Also does anyone know what amperage the Bosch cobra water pumps run off? Now on to the pics...

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 Old 01-06-2013, 07:08 PM   #32
 
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Ok. Days 2,3,4 and 5. Got everything in and made it back to Jacksonville running on all cylinders!! After many, MANY runs back and forth between o'rileys, rice-zone and ace hardware (i think i was on a first name basis with everyone), 3 long nights with hardly any sleep, its done!

So anyway the car runs good. Not perfect yet, but good. It feels slower right now since im running on wastgate pressure which is only set at 14 lbs, even though it creeps up to 17. The screamer pipe sounds dope and the turbo sounds like a damn jet engine when it spools up.

So day 2 was more or less spent mocking up the downpipe and making the new elbow that tied into my cpe downpipe. Took me and my brother about 2 and a half hours since we were working with a straight piece of 3" tube. Anyway, we ended up cutting 2 45 deg pieces and one 15 or so to make the turn after the turbo. I'm not 100% happy with how it looks but it works and it doesnt leak. So to feel better about it i wrapped it with heat wrap.






Day 3 was mostly running around trying to get shit made. I took my hot pipe to Ohio Hydraulics (great people if anyone in the Cincinnati area needs shit made) and had them machine and weld a flange for my blow off valve. They also brazed a -4an fitting onto my oil feed and gave me 2 -10an to 5/8" barb fittings for my heat exchanger. That night we finished up the downpipe and wrapped it, fitted, welded and wrapped the screamer pipe, and got the wasegate mounted to the manifold. ***Anyone using a turbosmart wastegate or going to*** This was an absolute -read- BITCH to get on! It probably took the 3 of us an hour using channel lock pliers to get on. What i ended up noticing was that the turbosmart has a sleeve that seals the bottom of the piston when its in the closed position. (i dunno if the tial or any other brands have this) Now the steedspeed manifold has a notch machined in the wastegate flange for this seal but it seemed that it was machined a smidge too shallow to allow the main body of the wastegate to sit flat on the flange. What we ended up doing was grinding down the seat of the insert so it let the wastegate sit flat against the manifold. Now again, i dont know if thats an issue with the steedspeed manifolds or not. I doubt it since most everyone else seems to have no trouble with them, just thought id share with you guys.

Day 4 was a rush to get everything finished since it was saturday and we had to drive back down today (12 hours). My 90 deg coupler from silicone intakes showed up at 1130 and we went to work getting the turbo put on, downpipe hooked up and the intercooler piping ran. Everything went super smooth until it came to the hotpipe. Unfortunatly our measurements, a.k.a. eyeballs, were off by about 4 inches. i think we just assumed the 90 deg coupler would be a little bit longer on the straight ends. so long story short the hot pipe is at kind of a wonky angle in order to get it to fit. I have a friend in town that im gonna have weld a few inches onto the end so that it lines up straighter. Now on to the funny (at least i thought it was) shit. While we were installing the heat exchanger, my dumbass knocked the fan off of the toolbox and of course it broke the housing and a blade off. So i just said fuck it and didnt put one on. Then i told my brother and girlfriend to put all the trim that goes against the windshield back on along with the hood and bumper while i cut a map to get the car running. When i got back and flashed it, the car fired right up, but when i went to back it out of the barn, i realized i had no power steering. Then i remembered that i forgot to put the serpentine belt back on. By the way, thats a bitch to do with a top mount setup since the downpipe blocks any and all access to the tensioner.
So after a few more tweaks to the map, we drove to my dad's girlfriend's house out in wilmington. (about 45 min) On the way there i rolled on the throttle on the highway and i could only boost 5 psi. When we got to her house it dawned on me...we didnt put clamps around the throttle body coupler . I borrowed a couple clamps from her neighbor and then the tune went stupid lean as soon as the car started. Imagine that. Luckily i brought my laptop with me and i added about 10% more fuel to the 20 that i already gave it and the car ran like a champ. Turbo spooled decently quick and i hit 14 psi and crept to 17 by 6000 with the afr's staying under 12. And thats where i left the tune for the drive back down.



Some thoughts on the LTA setup. Cruising BAT's are kinda high (40deg over ambient) but i think thats in part to not having a fan on the heat exchanger and a little bit of air in the system still. But when boost rolls on temps drop by the 10's down to just above ambient. Ill post logs about this later this week as well as a VD plot. As for the future i need to install my injector seals, get my hotpipe fixed and install my HPRV and buy a EBCS. I think im gonna get the Cobb one unless you guys think its a better idea to use another.

Also a big thank you to everyone who helped me along the way
JMOC-woop! @Raider; @djuosnteisn; @chuckms6; @QwkEVO; @Erich;
If i forgot you i apologise!
1st start video (since i know thats the only reason you guys even clicked on this thread)
2013-01-05_17-23-48_932_zpsc25d9fb8.mp4 video by ad_newcome | Photobucket

edit- how the fuck do i upload pictures off photobucket??? lol i clicked the picture icon and when i did the original post they showed up with the img tags but the pictures didnt show up
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Last edited by Erich; 01-06-2013 at 07:49 PM. Reason: MSF Database - Automerged Doublepost
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 Old 01-06-2013, 10:05 PM   #33
 
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glad to help the little bit i did lol i didnt know what you were up to!

if you take some pics of your waic setup maybe we can see whats up with it. ive actually removed the fan from my setup for now, whenever i reinstall it im just hooking it up to the switched side of my circuit so it comes on when the fan is off. when the car is running most of the time its moving so it seemed pointless.

my fan and pump was fused with a 10 amp fuse and didnt blow except for the time a relay rusted, so the pump pulls less than 5 amps.

do you have a thermal intake gasket? that helps with temps a bunch, as does egr delete/block off. to bleed they waic system i have a tee and a short length of hose that can extend above everything else in the system. when i bleed the system i pull the bolt that i use as a plug out and put a funnel in the hose, fill the funnel then run the pump for like 5 minutes or until it stops bubbling, then remove the funnel and replace the bolt and seal with a hose clamp. eventually i will get a small reservoir to make it cleaner and easier. it will not cool right unless it is completely bled. also i use a little water wetter, about a 3rd of a bottle.
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 Old 01-07-2013, 04:48 AM   #34
 
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Yea I think the biggest issue is air in the system. We were in a hurry to finish so we didn't take too much time to burp it. I'll get some pictures after work tonight.

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 Old 01-07-2013, 11:29 AM   #35
 
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Oh yea forgot to add, no tigs and no egr block off. I to have a remote filler cap for the system and its at the highest point when I hold it up to fill it. It's filled with 50/50 antifreeze right now since it was like 30 deg in Ohio and I didn't want the water freezing but I'm gonna drain most of it and refill with water and water wetter

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 Old 01-07-2013, 11:43 AM   #36
 
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Originally Posted by Navy_Mech2 View Post
Oh yea forgot to add, no tigs and no egr block off. I to have a remote filler cap for the system and its at the highest point when I hold it up to fill it. It's filled with 50/50 antifreeze right now since it was like 30 deg in Ohio and I didn't want the water freezing but I'm gonna drain most of it and refill with water and water wetter

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Get those on there, they help bat's a ton. More than water wetter

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 Old 01-07-2013, 04:57 PM   #37
 
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OK here's some better pictures of the setup with the heat exchanger and water pump. Sorry about the cell pics. And the slightly crooked pipe setup





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 Old 01-07-2013, 09:10 PM   #38
 
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It looks like you shouldn't have a problem. what direction does the water flow in and in what order?

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 Old 01-08-2013, 07:57 AM   #39
 
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From the pump up to the intercooler, then to the remote filler, back down to the top of the heat exchanger, out the bottom and back to the pump.
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 Old 01-08-2013, 10:21 AM   #40
 
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Sounds good then, you should be happy with just the tig and egr delete

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