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 Old 10-02-2015, 07:08 PM   #1
 
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Default Davychronic's corksport/gtx build

So I guess im far enough along now to start a build thread.
Bought this car in February because I felt it was appropriate to have an awd grocery getter since the winters here tend to suck. Im not trying to acheive the highest hp or test the strength of the internals, im just trying to make this car how mazda should have from the factory for the most part.<---This may have slightly changed... My factory k04 never had any issues, im am just tired of such a weak powerband. I will be very happy with 350whp<---not happy anymore, I need moar, so that was kind of my goal. Just enough to shit on a minor bolt-on 5.0 or equivalent since thats what most people have around here.

So mods before this project started goes as follows...
jbr pp2 intake
corksport internals
cs rmm
3 bar map
ill post a dl with that shit on e30 tuned by myself...

So I bought a @CorkSport; turbo because I like the td05 ra since ive used them in the past with a lot of success and I really like what cs is doing for our platform and not giving up on us. I also picked up the turboxs v3 exhaust mani after reading the long ass thread by @Turbo_Steve; and I appreciate what he has done for us and I wanted to keep my tmic setup and a lot of toob manifolds dont allow for it. Also went with the divorced cs downpipe mainly because its a small exit out of the turbo and tapers to 3 inch (im guessing to help with any creep associated with an bellmouth dp).

Then I started searching for a tuner, I read a lot of threads about tuners and called a few and ended up choosing the guys over at Purple Drank. What made me choose was the conversation I had with Will on the phone about what my power goals were and what I could expect out of what I got. This was about a month before I started my install that I started inquiring about a tune. He also made a couple recommendations about how to squeeze a few extra ponies so I picked up a jbr 3.5" intake and took my intake manifold off to check my valves' condition.

After checking my valves they looked like shit so I pulled the head and had it built with all supertech hardware 1mm oversized with inconel exhaust valves and 55lb valvesprings (20lb over stock)..
I also used this opportunity to change the vvt, timing chain, tensioner, guides.
I also figured id ditch the vtcs so i cut that crap out and did a little port matching.
I decided on arp8740 studs, I read the thread after the fact but still not concerned. So I torqued mine to 80ft/lb on a cometic .01 thickness increase hg.

So it went together pretty easy in a day by myself, added a DamondMotorsports vented catch can, blocked off egr, painted the valvecover wrinkle black, got some cpe inj seals (i added permatex #2 ), jbr tig, and a cpe deltacore tmic. I wrapped the header and dp in dei titanium and used dei gold on the underside of the tmic and shroud, probably forgetting some stuff but you get the picture I did a lot of shit.

At first I wasn't all too impressed with the new sound coming from the exhaust, so I will probably pick up a resonated tp from corksport to quiet the tone down and hopefully take the "raspy" sound away.
The new 3.5" intake is nice and quiet until you get into boost, then you hear the turbo screaming to life.

I dont want to go through and post a bunch of datalogs unless some specific parts that are requested but once the tune is finished I will be taking it down to Karls Performance and see what the real dyno numbers are compared to vdyno.

So after a bunch of going back and forth with Ryan from PD, he is suggesting that I scale down to a 3 gallon (e24) mix instead of a 4 gallon (e30) mix because my engine is flowing a little better than expected and I am running out of fuel at 20psi on e30. Honestly the main reason I am wanting to run e30 is because it is very plentiful for me in my area, in fact more plentiful than 91 octane (I can buy e30 straight from the pump).

So now I just ordered the Aquamist HFS-4 methanol kit with two 1.2mm injectors and I plan to tap my cold pipe for both injectors as suggested by Ryan.
I really wanted to make good power on e30 without meth but running out of fuel at 20psi only got me to 330ish on vdyno.

So now im walking down a slippery slope with my stock internals once its addicted to meth and probably going to build it next summer but ill see how far I can go with this turbo.
Attached Images
File Type: jpg 20150921_185026.jpg (4.54 MB, 158 views)
File Type: jpg 20151001_171928.jpg (4.83 MB, 150 views)
File Type: jpg 20151002_162149.jpg (4.58 MB, 155 views)
File Type: jpg 20151002_183459.jpg (3.89 MB, 157 views)
Attached Files
File Type: csv last k04 dl.csv (11.7 KB, 7 views)
File Type: csv e30 running out of fuel.csv (8.6 KB, 12 views)
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 Old 10-02-2015, 08:47 PM   #2
 
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Here is last vdyno on k04
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 Old 10-02-2015, 09:42 PM   #3
 
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Sweet setup. I'm really leaning towards this turbo in my speed3. Just a small note; worried about it being lean? or is that covered under the "base map"category?
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 Old 10-02-2015, 09:46 PM   #4
 
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Originally Posted by 09speedaddict View Post
Sweet setup. I'm really leaning towards this turbo in my speed3. Just a small note; worried about it being lean? or is that covered under the "base map"category?
There wasnt any knock, its on e30 and targets were 11.6 so the future revisions im sure will iron that out. It pulls strong up top, great turbo so far.
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 Old 11-02-2015, 07:07 AM   #5
 
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Here is my last e30 vdyno, we were barely started on this tune (2nd revision) before a 3 gallon mix was suggested
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 Old 11-02-2015, 07:15 AM   #6
 
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Nice numbers bet it's fun to take off from those stop lights!!
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 Old 11-02-2015, 07:18 AM   #7
 
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Originally Posted by JakeMS3 View Post
Nice numbers bet it's fun to take off from those stop lights!!
Haha where I live the closest stoplight is like 40 miles away, but yea it is pretty fun to drive. Just looking for a little bit more, trying to shoot for 400whp with meth now. I would like to push 26-28 psi on e30 and meth and see what it'll do.
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 Old 11-02-2015, 07:25 AM   #8
 
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Originally Posted by davychronic View Post
Im not trying to acheive the highest hp or test the strength of the internals, im just trying to make this car how mazda should have from the factory for the most part. So now im walking down a slippery slope with my stock internals once its addicted to meth and probably going to build it next summer
Quoted for lol
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 Old 11-02-2015, 07:38 AM   #9
 
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Originally Posted by Mazdazilla6 View Post
Quoted for lol
Haha thanks...Just not happy with only 20psi so away I go with testing the integrity of the factory internals for a few months (which will be in the winter and we get a lot of snow so wot wont be a common occurrence). I thought I would be happy with it until a new corvette beat me on a roll.
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 Old 01-01-2016, 09:26 AM   #10
 
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Has the final revision been completed yet? If so, what #'s are you hitting?

p.s. Did ya ever get another chance at the Corvette?
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 Old 01-01-2016, 09:38 AM   #11
 
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I tried to get some dyno time in before vacation to complete my tune and get some real numbers but weather wasnt cooperating. My last datalog put me at 367hp 373tq on e30 with 1.01cf

Originally Posted by Gitcherex View Post
Has the final revision been completed yet? If so, what #'s are you hitting?



p.s. Did ya ever get another chance at the Corvette?

Nah no chance at the vette yet and i havent got any good races down here in Dallas et either, kind of surprising but there is also fuggin construction everywhere so its kind of hard to find a safe place to run
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 Old 01-01-2016, 09:42 AM   #12
 
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Originally Posted by davychronic View Post
Haha thanks...Just not happy with only 20psi so away I go with testing the integrity of the factory internals for a few months (which will be in the winter and we get a lot of snow so wot wont be a common occurrence). I thought I would be happy with it until a new corvette beat me on a roll.
This is our life

Race his ass in the snow !!

a win is a win
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 Old 01-01-2016, 09:43 AM   #13
 
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Hahaha
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 Old 01-01-2016, 09:45 AM   #14
 
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Originally Posted by davychronic View Post
I tried to get some dyno time in before vacation to complete my tune and get some real numbers but weather wasnt cooperating. My last datalog put me at 367hp 373tq on e30 with 1.01cf




Nah no chance at the vette yet and i havent got any good races down here in Dallas et either, kind of surprising but there is also fuggin construction everywhere so its kind of hard to find a safe place to run
very nice, thats roughly what my goal is (for now lol). But I know the feeling all too well, no matter how much I taunt em, people ignore me lol.
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 Old 01-01-2016, 09:51 AM   #15
 
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Its good power, im happy with it. I have an aquamist meth kit ready to be installed but ill probably wait til i build the motor. On 93 I can hit 27psi super fast (like 3700rpm) and hold it to about 5500rpm wher i need to taper it down to 25psi hitting fuel limits. I need to datalog one of my 93 runs and see where im at there. Ive started to play with running 12.0afr on my e30 tune to get more boost but i richen it to 11.8 at 5500 and up.
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 Old 01-02-2016, 05:42 PM   #16
 
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Would not feel bad losing to a Stingray. Any 'vette made in the last few years is very quick, plus you have AWD slowing you down at higher speeds. I am considering this turbo and can only hope to be competitive with a new vette. Congrats on the install - 27 psi seems insane
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 Old 01-19-2016, 08:54 AM   #17
 
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Just to add a few things to my bulid thread



Got a pair of Corbeau RRS seats with heaters and brackets all from Corbeau. Install was pretty straight forward, still waiting on resistors to come in to fix airbag lights. Passenger rail is missing a spot fot the lower seat belt anchor so i bolted it to the floor. The seats are great, they sit about 2 inches lower than stock so it takes a little getting used to the new driving position.



Also got a set of Enkei Raijin 18x8 +40 wheels that are maybe a pound lighter than stock. For now they are wrapped in the Goodyear Eagle sport all seasons that were on my stock wheels 225/45 but come summer they will get summer rubber 245/40.


I started tuning my e30 tune leaner, starting at 12 and working my way up. Reason being is that i am making more power without detonation and you know the old saying leaner is meaner. Also stepped boost up to 23 psi so ill get some good vdyno numbers and datalogs to post.
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 Old 03-19-2016, 05:00 PM   #18
 
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Default Davychronic's corksport turbo build

So while doing a log tuning for 100% meth i bent a rod a couple weeks ago. 30 psi is too good to be true on these puny factory internals.



You can see third one down (cylinder 3) the rod is tweaked. So i went ahead and order Manley H beams and Manley pistons and rebuilt it in car.



You can see the spagetti factory rods compared to the beefy Manley rods.

So i bought a cylinder bore gauge and a couple other tools to make sure everything was within specs to do it without pulling it out and all went well. I honed it with 220 grit and finished it off with 320. I check flatness on the block and head (which i had built a couple months ago) and all was good. Installed everything without too many problems, Manley dis send me oversize pistons in a standard size box and they had a hell of a time believing me since "they are check sooo many times before they ship" but if they jad only paid attention to the weight on the box it could have been caught.



So after a bunch of bs with Manley, i finally got Edge to overnight me the right pistons and everything went smoothly from then on.



They look soooo pretty, shame ill never get to see them again, i hope.



Heres so in process pics



So now i got about 100 miles on it and all is well, ill check compression at 500 and see how its goin.


Ill post my log from when i bent the rod in a few hours, you can see where it happened.
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 Old 03-19-2016, 07:38 PM   #19
 
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Here is the datalog vdyno of the rod bending action
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 Old 03-19-2016, 08:03 PM   #20
 
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Looks like you were trying to have an excuse to go built with a curve like that.
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 Old 03-19-2016, 08:27 PM   #21
 
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Default Davychronic's corksport turbo build

Yea I was seeing how far i could push my luck. I was originally tapering boost up to redline but i missed the big torque shove so i said fuck it. Im trying to see how far this corksport turbo will go. Its clearly good for over 400hp.
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 Old 04-02-2016, 07:02 PM   #22
 
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So I guess to update this, i've passed my "break-in" period so I changed the oil with Royal Purple HPS 5w30. I turned the meth back on and got back to tuning. Im on my 4th revision and starting to wind down with my 91 and meth tune and numbers are looking pretty good. I dont expect to hit the dyno til i finish my e30 and meth tune. Im having a little trouble overboosting once the 2nd meth nozzle kicks on and I cant really get it to slow up so im tuning around it and making it work. It feels like the vdyno should be close, it pulls very strong all the way to 7k with no knock over .35 and im running 18.5* at 7k rpm so mild timing since i run a little more on my e30 tune without meth. I could flatten my torque curve out by tapering my boost up to redline but im happy with the big initial torque shove.
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 Old 04-02-2016, 07:12 PM   #23
 
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How much wgdc are you at?

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 Old 04-02-2016, 07:42 PM   #24
 
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Pretty much 90s across like 95 up top
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 Old 04-02-2016, 07:48 PM   #25
 
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Gotcha. May 2 I'm getting tuned with built motor, meth, and corksport turbo so I'm curious to see what this can do. How much meth are you running?

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 Old 04-02-2016, 08:01 PM   #26
 
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And also how loud is that turbo at 28 psi lol. I know it screamed at 22 before the zoom zoom boom

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 Old 04-02-2016, 09:05 PM   #27
 
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I spray 9gph of 100% and get 85%idc at 7k rpm. This is about all the turbo can do i think. Even with meth boost temps come up to intake temps at high rpm so come summer time im sure ill have to back down a frw degrees of timing

Its a good turbo tho, you wont regret your purchase. It feels like the turbo that should have came on the car, excellent powerband.
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 Old 04-02-2016, 09:36 PM   #28
 
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That's still solid power. Yea I'm gonna run 100% meth 10gph. I'm already impressed with this turbo
It's definately a perfect turbo for this car. It pulls hard to redline. I would say this is like a bnr s3.5 lol

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 Old 04-03-2016, 05:41 AM   #29
 
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Ive never had the bnr so I cant really compare but its a great turbo for its size. Ive started looking at a pte 5862 and water to air intercooler. I am well passed the efficiency range for this turbo and its just blowing hot air.
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 Old 05-03-2016, 09:44 AM   #30
 
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I've been super impressed with this turbo so far too, been running 24psi on 93 and it pulls all the way to redline.

Awesome build, keep it up.
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 Old 05-03-2016, 11:06 AM   #31
 
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In for rest of build, been considering this turbo for my BT build, or maybe even going bigger lol. Always wanted a GTX3071R/GTX3076R (can't decide). That and quite a few people up here in MN have BNR's so I want to be different haha.
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 Old 05-03-2016, 12:42 PM   #32
 
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Default Davychronic's corksport turbo build

Yea my build is changing direction, ive been meaning to update this.
Ill attach my last datalog it is on e30 and is about 10-15 more hp than my 91 map thanks to leaner afrs. The only way i could get decent control of boost was to taper it up to redline which killed peak torque but gave me a good flat curve. In my opinion this is the best turbo for the stock block. I have absolutely no gripes, it would be better with an ewg if you are trying to spool it up as fast as you can but on a stock block thats not recommended. I am at the limit of the turbo and my tmic at the moment and another build is under way. Im running 100% wgdc at redline and can only get 28-30 psi which is great and well beyond the efficiency range of the turbo.


Im starting a new build because i want 500-550 awhp that will take me the next several months to get everything together and this is how im going to get there:

sp63 stage 2 long block (the reason im going this route since im already biult is because the down time and cost would be very similar if i tore my motor apart, sent my crank and cams in to have them keyed and have my block machined and etc. it comes out to about the same cost but with much less downtime if i just buy the long block already keyed)
cp-e havoc intake mani and fuel rail
im exploring a few options on fuel controllers still, id like to have my aux injectors to be spraying all the time to keep my valves clean but im looking at 4 750cc injectors and a walbro 450lph pump
treadstone vertical flow fmic TRV1859 with a blow through maf and custom piping
i intend to keep the meth but ill be spraying only one nozzle and more for temp control and knock protection
cp-e atmosphere barebones kit, tial vband mani and dp
tial 44mm mvr ewg
and either a gtx3076r or gtx3582r
still staying self tuned

Im split on turbo choices because I still want to be able to track the car but I dont want to be pushing the turbo passed its efficiency range either. I dont think the gtx3582r would be so great on the track so im really just researching a lot of other guys with the 35r to see if i can make 26-28psi by like 3700-3800 rpm.


I am about to install my new 8 puck RD Motorsports clutch and act streetlite flywheel next weekend to make sure i get that broken in before the new motor goes in. Hard to break in a new motor with a new clutch. Ill try to post a pic of the clutch later today.




But yea i highly recommend the corksport turbo to anyone looking for good power on a stock block, i dont regret my purchase at all. I plan to have my new build finished by August or September if all goes well. Ill probably do it in phases when I have time. Id like to break the new motor in with the corksport turbo. Come Christmas time i'll have a ton of goodies to sell
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 Old 05-03-2016, 07:30 PM   #33
 
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Originally Posted by davychronic View Post
......Come Christmas time i'll have a ton of goodies to sell
Hell yee in for that! Hahaha
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 Old 05-03-2016, 09:24 PM   #34
 
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Whats up with that boost control. Geez
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 Old 05-04-2016, 05:22 AM   #35
 
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Default Davychronic's corksport turbo build

Originally Posted by blackms3_71 View Post
Whats up with that boost control. Geez


Yea its tough to slow spool down with meth especially when you are working at the upper limit of the map sensor. I debated getting an ewg to make it easier but im just changing it all so its about as smooth as i could get it. Took me a lot of logs just to get it where it is, ive tried so many different ways to slow it down once it hit 28. I tried load targeting, throttle closing, lowered boost targets and wgdc, wgdc correction, everything i could think of didnt work so i had to taper it slowly which is ok it still pulls hard. See the way i have my meth set up is one nozzle comes on at 15psi and a second one comes on at 25psi and its when that second one comes on that makes the turbo hard to slow down. This was the best method i think to keep it from bogging from coming on with too much too early. Two different size nozzles too.
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 Old 05-08-2016, 09:39 PM   #36
 
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@herzloglover; @lasserudn;
The gnarly Corksport turbo build I was talking about at ENM-MN
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5.3 swapped, cammed, pnp'ed heads, long tube headers
Got bored and now I'm selling it
SOLD | '07 Cosmic Blue Mica MS3 GT #Genjuan | Hypnotic Tuned | M2 Catless DP w/Titanium Header Wrap | Damond "Gold" RMM | AutoTech HPFP | HTP 3.5" Intake | Turbosmart 50/50 | RallyArmor Mud Flaps | JBR Weighted Knob | JBR Shift Weight | H&R Coilovers | Grimmspeed EBCS | Corksport FSB w/billet brackets | Sparco Pro Corsa's wrapped in Dunlop Direzza DZ102's |
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 Old 08-25-2016, 07:43 AM   #37
 
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Guess I should update this, never made it to the dyno to see what this ended up making but it felt strong and the corksport turbo is great. I highly recommend it for someone who is still stock block that wants a little more power for pretty cheap.

I have started a new build it probably needs a new thread but im going with a cpe precision vband mani with a pte5858 with a ported s compressor housing and .82 a/r exhaust housing turbo with a tial mv-r wg that i am going to build a custom recirc pipe into the kozmic dp.
I have a tr-10 intercooler on the way and a couple sets of universal intercooler piping kits, 2.5" hot side, 3" cold side with a tial qr bpv.
Waiting on Damond to release the intake mani adapter to run the focus manifold
Still need to make a custom oil drain line so im waiting on everything to show up before i start disassembling everything

Should have a ton of shit coming up for sale in the next couple months like the corksport turbo,xs v3 exhaust mani that is wrapped in dei titanium, corksport divorced downpipe also wrapped, cpe deltacore anodized in black, hks bov

So far all I have is the turbo but in the coming weeks the rest of the stuff should trickle in
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 Old 08-25-2016, 06:15 PM   #38
 
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Looking forward to see how you push this set up. Are your goals still only a little more than you got out of the Corksport, or have those changed also?
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 Old 08-25-2016, 06:25 PM   #39
 
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Originally Posted by sheston View Post
Looking forward to see how you push this set up. Are your goals still only a little more than you got out of the Corksport, or have those changed also?


Id like a solid 500-550whp and id like to stick with a 3 bar map but we will see how it turns out when i start tuning
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 Old 08-29-2016, 12:15 AM   #40
 
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There's a good chance you will have to run a 3.5 bar map sensor to run the power you wan't, boost will possibly be out of range for the 3 bar, especially to catch head lifting boost spikes.
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