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Old 12-05-2009, 01:35 PM   #1
dbsharp
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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
JDM FMIC
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
Downpipe
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.
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Last edited by dbsharp; 12-21-2009 at 10:36 PM.
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Old 12-05-2009, 02:03 PM   #2
twokexlv6coupe
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niioooceeeee


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


and did you already make that ram horn mani? i might be interested in one of them suckas, if u decide to sell some
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Old 12-05-2009, 02:45 PM   #3
c mak
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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
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Old 12-05-2009, 06:47 PM   #4
dbsharp
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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.
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Old 12-06-2009, 09:45 AM   #5
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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.

ETA?
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Old 12-06-2009, 01:42 PM   #6
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i'd try to eliminate most of those couplers on the charge pipe.
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Old 12-06-2009, 09:35 PM   #7
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Quote:
Originally Posted by weirtech View Post
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.
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Last edited by dbsharp; 12-06-2009 at 09:38 PM.
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Old 12-11-2009, 10:07 AM   #8
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Quote:
Originally Posted by twokexlv6coupe View Post
what's the red machine in the first pic? can't be a mandrel bender, since your doing pie cuts
It's a horizontal band saw. Perfect for cutting long lengths of pipe.
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Old 12-11-2009, 10:16 AM   #9
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did you make good clearance with the crossmember with that manifold?
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Old 12-12-2009, 12:30 AM   #10
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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.
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Old 12-12-2009, 09:09 AM   #11
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manifold looks sick bro, i wish i got a welder.
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Old 12-12-2009, 09:23 AM   #12
dbsharp
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I don't own one. I borrowed a friends. Now I just need to make some friends with tig welders.
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Old 12-12-2009, 08:26 PM   #13
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Every part is fabbed up. I am just waiting on my last part to come in so I can bolt it all together!

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Old 12-13-2009, 02:00 AM   #14
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Great work!
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Old 12-13-2009, 10:00 PM   #15
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I updated the first post with new pics.
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Old 12-13-2009, 10:10 PM   #16
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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.
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Old 12-13-2009, 10:27 PM   #17
dbsharp
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go for it man!
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Old 12-17-2009, 02:52 PM   #18
dbsharp
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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!
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Old 12-20-2009, 05:08 PM   #19
dbsharp
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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.
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Old 12-20-2009, 05:56 PM   #20
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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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