Turbo Focus build #2

[sutyak]

This second build is going to stretch into 2013 and will be broken down into phases. Since I will be the one tuning it this will greatly simplify the adjustments I have to make.

Phases
1) Swap out the IHI/16T hybrid turbo for a GT2871r (Target: June 2012)
This will involve welding in a wastegate flange for an external wastegate, the dump tube, and a few inches of new downpipe. The turbine outlet is a 2.5" v-band flange, which will immediately open to a 3" downpipe. Tune for the 8psi wastegate spring. No boost adjustment yet.

2) Cossie knock-off intake manifold. (Target: July/August 2012)
This involves moving the power steering reservoir and re-routing some lines. I may do a detailed write-up of this if I have time. Adjust tune. May add boost controller and go to 10psi if logs look OK.

3) Built motor (2013)
There are still many variables here to account for. The only part I have in hand at the moment is a set of 88mm 10.1:1 Supertech pistons. These were used in a 2.3 build for a few thousand miles, and started life closer to 10.6:1 and were professionally milled to a lower compression.
The current plan is to use the stock 2.0 head and cams, but that could change.

My original goal was ~400whp, but instead of jumping ahead I think I'm going to shoot for ~300whp and leave some room for future fuel system upgrades for a phase 4. Basically I'll push it until I nearly max out the stock fuel system.
I considered lower compression pistons, but I decided I'd rather run the slightly higher compression to start with and if I want to go lower I'll use a thicker had gasket. If I started with lower compression and wanted to go higher it will cost much more to mill the head vs. buying a thicker head gasket.

This build will not be real-time like my first one (I have 2 kids now), but I will provide photos and write-ups once phases are complete.

NOTE: This is not now nor will ever be a dyno queen. I will post dyno results if I happen to go with a group for a dyno day. Please don't skip around this thread and expect to find a dyno sheet. This isn't that kind of build. I'm far more likely to provide datalog information and 1/4 mile track times than dyno charts.

Parts list (on shelf)
GT2871R turbo (T3, 63ar, 2.5" v-band out)
Tial 38mm wastegate & dump tube piping
T3 Log manifold from build #1
55lb injectors
Cossie knock-off intake manifold

Parts list (Still to purchase. PM me if you have and want to sell.)
2.0 Connecting rods (leaning towards K1)
Rod bearings
Head gasket (can't decide between Fel-Pro or Cometic and also thickness)
Bottom end gasket kit
Top end gasket kit
Torsen LSD
Clutch (Exedy Hyper Single or maybe even the Clutchmasters FX700)
MAFia for 2005+ Ford (had one, went to 3" MAF so I sold it. Now I think I'll need one again)
60lb injectors
Drag wheels + slicks
Boost controller (might go with electronic)
Larger intercooler

Parts credit (I'll had to this for any person/company who cuts me a deal on parts)
- Top Speed for 38mm Tial wastegate ($150 lightly used was a good deal)
- Tantalus for pistons
- koke'sfocus for intake manifold

Pictures







I'm more of a Coke Zero guy, but for some reason there are Pepsi cans around when I take pictures.


I figure this might help some people if they are considering the GT2871r.
If my calculations are correct my Phase 1 at 8psi will be peak at the intersection of 1.7 Pr and 27.7 lbs/min at 7K RPM. I can't wait to run it at 20+psi/2.7Pr and let it ride that island to 45lbs/min! I'm fairly certain that will require a return-style fuel system.
These are just estimates. I'd have to do some data logging to map out real-world results. I might do just that. Mapping the lb/min and RPM from the datalog on the compressor map should be very helpful. I did that with the IHI but didn't post it.


-3AN .035 oil restrictor


Compressor outlet adapter. These are surprisingly expensive at $40 from ATP Turbo.

[sutyak]

I started installing the GT2871r today. The fit isn't as perfect as I thought, but it does fit. The turbine housing angle is a bit different than the IHI I built the manifold for and the result is a rather large gap between the block and the turbo. The new turbo is positioned up about 1" and out 1", putting the compressor housing almost against the coolant lines.
I did break one of the plastic coolant T's on removal so I'll be hitting Napa for another one. (PN 660-1593)

I'm still debating whether to dump the wastegate or pipe it back into the exhaust. I'll probably run it dumped at first.

I also broke off one of the nipples on the evaporator for probably the 4th time. I'm getting tired of gluing it back on.

Completed:
- Remove old turbo
- Mock up new turbo and determine necessary modifications to piping

To do:
- Modify downpipe for 3" V-band
- Modify hot site pipe (eliminates a 90* bend)
- Modify ambient pipe
- Route coolant lines
- Mock up wastegate
- Weld in wastegate and route dump
- Datalog and tune


The gap. It's unnecessary but hey I'm not going to hack up my manifold if I don't have to.


IHI RHB52/16T hybrid vs. GT2871r




The new beast:


And one more for fun:

[sutyak]

...and one for my SCS peeps.
Yes, I use that water bottle every single day.

[yeahloh95]

Very cool thanks for all the info

[sutyak]

Downpipe is complete and I also replaced the horrible compression style clamps with 3" v-band clamps. Next up is the wastegate, which I decided to route back into the exhaust. I'm going to mount the wastegate on the underside of the manifold (since there is room), that way all pipes will be nice and short.

Old downpipe for the Tbird IHI compared to the new downpipe for the GT2871r:




v-band!


Old leaky junk vs. v-band

[venom]

Damn dude. Cool shit.

[John4cam]

Are you doing all the fab work?

[sutyak]

Are you doing all the fab work?

Yes sir

[sutyak]

Finished up the wastegate flange tonight. I know the manifold isn't beautiful, but it was also one of the first welding project I ever did 5 years ago. So, don't judge too harshly on those old welds. I've had to repair a couple cracks, but overall it's actually held up very well.. it's just ugly. :)
Next up is the return line from the wastegate to the exhaust. Last fab stuff is some minor modifications to the intercooler pipes, coolant lines to the turbo then ready to dial in the tune!
EDIT: I decided I want to use a flex pipe between the wastegate and main exhaust pipe. I'll work on something else until that arrives.

38mm flange for Tial:






I haven't positioned the vacuum ports yet.


Fairly direct shot to the downpipe from the wastegate. That is tomorrow's project.

[sutyak]

I'm making progress on the wastegate return pipe. I determined I do not like the angle of entry into the exhaust, so I'm going to cut off that angled part and make it more of a 45 degree entry instead of 90.
Overall I'm pleased with the progress, considering how little time I'm able to put into it.
I ended up making a 38mm flat flange because I was short one. The moral of that story is: keep everything. :) The piece of metal was from my buddy's F150 diesel that we replaced the water pump in 5 years ago. It was part of the A/C bracket.

Tomorrow I'll finish the wastegate return, modify the hot side intercooler piping, modify the ambient pipe, and if I have time hook up the water and oil lines to the turbo.

Sorry for the cell phone pics tonight.

The A/C bracket, I mean flange:


Wastegate return


This is the angle I'm going to tweak to more of a 45:


Where that flange was used:

[Viper_ed]

Just let the waste gate dump to the atmosphere.

[sutyak]

Just let the waste gate dump to the atmosphere.

Don't want the noise. From all I've read dumping it to atmosphere doesn't result in any hp gains, just more noise. I also like hearing the turbo and not just the exhaust.

[Martin0660]

Nice work!

FWIW, I run mine dumped and most are hard pressed to notice it's dumped if it's on high boost. Flow comes off a turbine wheel in a spiral pattern following the outsdie of the pipe. When you bring a gate dump back into the stream it interupts that pattern and causes turbulence than can hurt flow. EVERY application and placement is different and most of arent pushing turbine flow to the limit that it matters ... I dumped mine for packaging reasons and am happy with that decission.

On EDIT - Further to my point about turbine flow control and effects, notice the evolution of turbine wheel design ... Look at your IHI versus your GT series. Notice how the blades are shaped different and more curved as the designs evolved. Further, here is my Precission 5557 turbine, this is another step in that design, the curve is now even further evolved to deal with flow as it comes off the tips and move toward more laminar flow versus spiral flow ...



Again, likely not important to your goals, just a fun discussion ;)

[sutyak]

Nice work!

FWIW, I run mine dumped and most are hard pressed to notice it's dumped if it's on high boost. Flow comes off a turbine wheel in a spiral pattern following the outsdie of the pipe. When you bring a gate dump back into the stream it interupts that pattern and causes turbulence than can hurt flow. EVERY application and placement is different and most of arent pushing turbine flow to the limit that it matters ... I dumped mine for packaging reasons and am happy with that decission.

On EDIT - Further to my point about turbine flow control and effects, notice the evolution of turbine wheel design ... Look at your IHI versus your GT series. Notice how the blades are shaped different and more curved as the designs evolved. Further, here is my Precission 5557 turbine, this is another step in that design, the curve is now even further evolved to deal with flow as it comes off the tips and move toward more laminar flow versus spiral flow ...

Again, likely not important to your goals, just a fun discussion ;)

Very interesting. That info could help me decide exactly how to dump the wastegate back into the exhaust to follow the spiral flow and not interrupt it as much.

I forgot to mentioned I caught my pants on fire tonight.
I was welding in cut-off shorts and my leg felt abnormally warm.. a 5" wide section of the frays was burning.

[yeahloh95]

very good info bob , i really want a turbo on my focus too

[PaxtonShelby]

Really cool project. Can't wait to see the finished product.

[sutyak]

Never a dull moment. It's very convenient having a spare motor to mock up things, but I forgot that I don't have any accessories on that spare motor! After I finished welding up the wastegate return and went to mount it on the car I quickly realized the wastegate is hitting the alternator! I could 1) cut and reweld the wastegate routes 2) grind down part of the alternator or 3) grind down part of the wastegate. The wastegate lost.
The side wastegate nipple was hitting the alternator, as well as about 1/8" of the aluminum housing (vac area not the steel exhaust route). This all actually turned out to be a blessing, as I found that part of the diaphragm was pinched between the halves of the aluminum housing. I disassembled the wastegate nearly completely in order to clock the housing so the nipple wouldn't hit the alternator. A bit of grinding later and it fits fine.





Wastegate ground. Please ignore the funky old welds on the manifold.


If only all my cuts were perfect then all the welds would look like this:


Fits now!

[Viper_ed]

Welds look like crap, but you get my respect!!! I love when people tackle new things themselves instead of just writing a check.

At the end of the day you can step back and be proud of what you have done!

[sutyak]

Welds look like crap, but you get my respect!!! I love when people tackle new things themselves instead of just writing a check.

At the end of the day you can step back and be proud of what you have done!

You're right, the welds don't look like they are from someone who was paid to do it. However, I assure you they are solid and are penetrating well. My cuts are really what are bad. There were some rather large gaps I had to span. If you can span a 1/4" gap with a 110v MIG welder (.025 wire 100% CO2) and it look perfect, then you are the man. I don't have any saw specific for tube cutting, so literally every joint is going to have a slight gap due to a flat cut mating to a curved surface.
If you're talking specifically about the manifold, then yes it looks simply awful. It has been cut/ground/rewelded in a few problem spots probably 5 times. I determined it was stress cracks from a warped flange. Hopefully that has been resolved.
Looking at some of my old welds that look like they just sit on top of the pipe I think it's a miracle they have held, but they have for 5 years.

That reply was too wordy. I should have just said fu my welds are great.

I do appreciate the DIY complement. People really take for granted how much R&D goes into the products they pay for.

[mr4teth]

That reply was too wordy. I should have just said fu my welds are great.

I concur! Very cool project!