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-   -   DBSharp's Turbo Fabrication thread. (http://www.cb7tuner.com/vbb/showthread.php?t=149568)

dbsharp 12-05-2009 01:35 PM

DBSharp's Turbo build
This is a pretty low budget build I put together. I have spent right under $800 to convert my car from NA to boosted.

Parts I got for free from Errol (yardiexd40): This stuff was part of his old setup. His new setup is going to be bad ass.
Holset HY35W type-D turbo
Tail Knock off wastegate
Waste gate dump tube parts
Front torque mount for a suburu.

Parts that I am designing/fabricating for this build:
Ram horn turbo manifold
BOV mount tube
Front motormount brackets
Turbo braces
Wastegate dump tube

Parts I bought, not including all the minor BS:
Turbosmart BOV. Got this for $40!
2.5" intercooler Charge pipes and couplers
Down pipe parts
Weirtech flanges for the manifold
K&N filter










I expect this to make 250 to 300 WHP once it is done. I have dsm 450cc injectors and a somewhat small intercooler. If I want to get more power out of this setup later, I could upgrade these parts and crank up the boost! Of course I wont do this unless I get the $$ to build a motor too.

twokexlv6coupe 12-05-2009 02:03 PM

niioooceeeee :tu:

what's the red machine in the first pic? can't be a mandrel bender, since your doing pie cuts :confused:

and did you already make that ram horn mani? i might be interested in one of them suckas, if u decide to sell some ;)

c mak 12-05-2009 02:45 PM

Nice work Dan!!!

I wish i could do some of that work you do!! The mani looks awesome. Can't wait to see the final project pics! Makes me want to go turbo again, damn it!!!! LOL

dbsharp 12-05-2009 06:47 PM

thanks for the compliments.

The manifold will turn out nice once its done, right now it still has a couple pin hole leaks in it. I am going to give it to a buddy of mine who is going to go back over the manifold with a tig welder. I have A LOT of hours into the manifold so far, I'm not sure It would be worth my time to make them to sell them.

drummersteve7 12-06-2009 09:45 AM

dude. your car pulled on the h22 and boosted ford.
now your gunna boost!

I fuckin love you man!
great work. nice to see your doin it yourself.


weirtech 12-06-2009 01:42 PM

i'd try to eliminate most of those couplers on the charge pipe.

dbsharp 12-06-2009 09:35 PM


Originally Posted by weirtech (Post 2331160)
i'd try to eliminate most of those couplers on the charge pipe.

I don't own a tig welder. If i did I would only have a couple of them and would have welded up the rest. All of the pipe is flared at the end, so I don't foresee any issues with the couplings.

Oh. By the way, do you recognize the flanges on the manifold? they are all weirtech flanges. I was going to call in a favor and get some cnc lazer cut by a friend. I even had the flanges drawn up and dimensioned in autocad. One reason I didn't was because of all of the dimensions that are necessary for the head flange. I would rather just pay you for them than to use up the favor. Who knows what part I may need cut out in the future.

ETA? I have to find a circlip and seal for the compressor housing on my hy-35 before it will be together. I am waiting on a reply from gpopshop. Maybe I can get them there.

Sobeman81 12-11-2009 10:07 AM


Originally Posted by twokexlv6coupe (Post 2330157)
what's the red machine in the first pic? can't be a mandrel bender, since your doing pie cuts :confused:

It's a horizontal band saw. Perfect for cutting long lengths of pipe.

h22sparkle 12-11-2009 10:16 AM

did you make good clearance with the crossmember with that manifold?

dbsharp 12-12-2009 12:30 AM

I designed the manifold to fit the turbo I have into the space I have available. It clears the crossmember. I did design it to be used with the traction bar I plan on making. There isn't as much room for the downpipe as I would like, but with a traction bar there will be more room.

I am using the stock radiator and one of the fans. The other fan is going to be a pusher that sits between the intercooler and radiator.

I only have two pieces left to make. The turbo brace and the waste gate dump tube.

I get my last part early next week, so this should be together sometime next week! I want to get the wideband working good before I go beating on it much.

gdout90accord 12-12-2009 09:09 AM

manifold looks sick bro, i wish i got a welder.

dbsharp 12-12-2009 09:23 AM

I don't own one. I borrowed a friends. Now I just need to make some friends with tig welders. :evil:

dbsharp 12-12-2009 08:26 PM

Every part is fabbed up. I am just waiting on my last part to come in so I can bolt it all together!


chessboxer 12-13-2009 02:00 AM

Great work!

dbsharp 12-13-2009 10:00 PM

I updated the first post with new pics.

drummersteve7 12-13-2009 10:10 PM

nice danny, wish I had access to welders.

thinking I might get one before I move on to my full build.

gunna wanna do my own exhaust.

dbsharp 12-13-2009 10:27 PM

go for it man!

dbsharp 12-17-2009 02:52 PM

I returned my distributor kings dizzy (cam sensor code) and they sent me a brand new one, but it was the wrong part. I would have this car running right now if it wasnt for that. I will have it running as soon as the new one comes in! I think I fixed the wideband too, so I will be able to tune it as soon as it gets running!

dbsharp 12-20-2009 05:08 PM

This bitch rolls out now! Spins through first very quickly, and spins in the powerband of second!

According to data logging, I am using every bit of these 450cc injectors, they are just big enough! I haven't even had to hardly touch the basemap I made for my car, afr's are pretty much already where I wanted them to be. I am going to add in some more ignition and see how this motor likes it!

Now to the bad...

The car smokes, bad, but only after I am off the throttle. There is no iol in the intake and none on the sparkplugs. I know its leaking out of the exhaust side of the turbo.

The v-band clamp for my down pipe won't seal up for some reason! this is especially annoying when the turbo is spitting out oil smoke. I think the clamp might be the reason why. Ill look into it when I have the time.

drummersteve7 12-20-2009 05:56 PM

nice man. glad to hear you got it up and goin.

get that smoke fixed, and show some ripper vids mang!

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