This is my first build thread on HMT, though lurked for years.

I am building this engine and turbo setup for a customer. We plan to swap the built engine in by June. Current hp goal is 400hp. I do not expect it to hit this on the first pull. Given this is a unique build and none that I have seen have taken the T8D to this level, tuning and boost is going to be done in stages. But more on that when it comes time for it.

FYI this is the same 1.8L engine Jeff turbo'd awhile ago, except going into the hatch. As far as the rumored Thrust washer/crank-walk problem. His is the only documented case of it happening. AS stated, the engine will be tuned in stages, so if that does proove to be a problem a spare block will be machined to fix.

The thing with an engine with little aftermarket support, breaking parts is just part of the game. There is no "formula" with these engines. Anyway, enough bable.


Engine : 2002 t8d 1.8L (81mm x 87mm) iron block

HP target: 350hp medium boost, 400hp+ depending on other factors

Actual Parts list to date:

TURBO KIT:

Holset H2A Turbo
3/8" laser cut flanges
TurboSmart 38mm Wastegate
1.5" S.S. Wastegate dump tube
3" S.S. Downpipe
equal length Sch.10 S.S. Turbo Manifold (custom)
-4an Oil Feed Line
Tuner Toyz Block fitting
-10an Drain Line
other -AN fitting (all)
2.5" Alum. I.C. piping (2mm thick)
S.S. T-Bolt Clamps & 3-4py couplers
3" Blox Velocity Stack
6" Blox High-Flow Filter (for velocity stack)
Precision 780cc Injectors
Turbo-XS Type-H RFL BOV
28"x8"x3.5" Intercooler
Manual Boost Controller
Custom Catch can w/AN fittings.

ENGINE UPGRADES:

Cometic Head Gasket (may use 3-layer OEM steel)
Wiseco 9.5:1 Forged Performance Pistons (81.5mm) &
Performance Rings & Wrist Pins
Custom Puater Rods
TOGA HP Main Bearings
TOGA HP Rod Bearings
TOGA High Volume Oil Pump
Polished oil pan w/ welded drain plug
Polished Fuel rail w/ -6AN Return line fitting
60mmx65mm BBTB Throttle Body
Spec stage 3 clutch
Custom Billet Steel 11lb. Flyhweel
Custom Grind .375 Turbo Cams
Megasquirt v3 ECU

ADDITIONAL UPGRADES:

3" S.S. Turbo Back Exhaust
3" 120mm tip Turbo Muffler
2" Core 16" Alum. Radiator
12" Slim Fan
Custom radiator hoses w/S.S. T-bolt Clamps
S.S. fuel return line & -6AN fittings
Walbro 255 fuel pump
Liquid filled Pressure Gauge
Obx R.R. FPR
AEM Uego WideBand O2
Autometer Cobalt Gauges (boost/oil/Tach, etc.)

Now for the pics of the current progress:
































Now that most of the parts are in, the fabrication and real fun can begin.

 

Pauter rods, but a cdm turbo? and a 57 trim at that? Going to take some pressure to get that power, and a 57's map is pretty small.

Still sound like a cool build, how are the transmissions in those?

 

i agree... ballerest of rods, and a small chinese turbo to back it. i doubt that that turbo can push 400whp on that motor...

build sounds awesome though, KEEP US UPDATED!!!

 

cdm turbo ? *EDIT Chinese Domestic Market? lol Actually has Japanese internals, but yes, it is not the ideal turbo for 400hp as stated below.

I do not expect to get 400hp reliably out of this Turbo, it is more so used as a stepping stone. This build is also being worked within the customer's budget. I will agree that we will probably reach the Turbo's efficiency range well before 350hp. I can say he will be more then happy at that point though and will be until he can afford a larger Turbo, say SC61 or similar. Basically the engine and other items are being build to handle 400 or more hp. When the time comes to upgrade the Turbo/injectors etc. not much else will have to be touched.

I will be using a SC61/GT35r in my own T8D build. But thats for another thread.

THe trans will hold up just fine. Almost identical to the Escort GT 5-speed. He'll snap a shaft before ever breaking anything in the trans. And even those won't go unless he runs some Slicks at the track, ggiven he can drive. He is already expecting to get larger shafts at some point, and they do make them.

 

g/l with build. Just out of curiosity, can you use honda pistons? b18 standard bore is 81mm. Thatd work out nicely for you for a source of "cheaper" pistons

and cdm is the ching chong meow, or Chinese Domestic Market, or, where you bought your turbo. When your turbo dies on you, you should buy a holset hx35 or hy35. They go for ~$200 used, will last forever, make boost fast, and make shittons of power, more than enough for 400hp goals

 

Highly unlikely on using the B18 pistons. Bore may be the same, but I doubt the wrist pin size and skirt/overall height are the same, let alone giving the same stroke. Forged pistons can be had for $375-400 a set. Not bad given the minimal aftermarket support. Rods are the same as most other applications as well, $775 +/-

Honestly I doubt the customer will be driving the car long enough for this Turbo to fail. It's not his DD, and he is in the Military (in Iraw right now). But if it does, you bet I'll be pushing him for a good upgrade.

EDIT: FYI I am looking at a Holset H2A for my own T8D build

 

you will make 900 with that fan

 

I never understood why the chinese chose that size (bigger turbine than compressor) over all other sizes when they decided to mass produce a turbo. Why not a 60/63 and a 42/48, two of the more commonly preferred/used sizes? and then their t70 pile of junk. eh, if i was yellow and slant-eyed, I would rule the world, and make turbos not of awkward sizes.

 

Damn nice build. Got more pic's?

 

Haha my dad has the same car, makes me want to show him since the warrenty is up like 5xxx miles ago.