Just completed my 240 turbo install PICS included::
 

Hey guys, My install went fairly well over the weekend and yes, I do have pics through imagestation. Things were very slow and this damn car is quite tough to work on because everything is cramped. Battery relocated into the trunk. Custom top mount turbo manifold, a very large mitsubishi turbo (don't really know the specs of it but it is damn hugh!!), braided oil lines, custom 3" down pipe, 3" cat-back exhaust, CCA front mount intercooler (big props for an awesome product - thanks again to Rene and her team @ CCA).

Now here is the thing: Car turns over and starts fine. No problems with the idle. Have not completed the exhaust yet so there is nothing after the down pipe. My concern is that when the car is idling, the turbo will actually stop spinning. Now this is a very big turbo (comparable to a t4/t4) but does is stop spinning?? Everything is fine if you rev the engine the turbo spins up fine. The oil line has been checked and I'm using a -3 An braided line. The car runs fine, Idles great and no leaks which is awesome. But I was concenred about the turbo not spinning. I'm getting the exhaust done this week and then it has to be tuned. For the fuel side I'm using an SAFC 2 and a walbro in-tank 255 lph pump and I'm only going for about 7-8 psi. I know the KA motor can take a beating but I"m starting off slow and going from there.

So what do you guys think?? Also I would like some feedback about the turbo not spinning at Idle but it currently is an open downpipe.

Enjoy the pics and I would like to hear some feedback.

EJ O0

http://www.imagestation.com/album/in...?id=2121119668

Re: Just completed my 240 turbo install and have some questions...
 

don't worry about it. I doubt my t3/t4 spins. The t3/t4 on my buddy's accord doesnt spin at idle. If you give it some gas it should definitly spin though.

I hope you're not expecting the stock injectors to support THAT turbo at 7-8psi ???

Re: Just completed my 240 turbo install and have some questions...
 

any other place you can host pics where i dont have to sign up to view them?

Re: Just completed my 240 turbo install and have some questions...
 

nicee set up what is the sise of that turbo my friend is working on boosting his ka should be fun

Re: Just completed my 240 turbo install and have some questions...
 

You don't have to join, just click here:
http://www.imagestation.com/album/pi...668&mode=guest

Re: Just completed my 240 turbo install and have some questions...
 

Don't worry about it not spinning at idle, that's normal.

But yea... get some bigger injectors.

Re: Just completed my 240 turbo install and have some questions...
 

Re: Just completed my 240 turbo install and have some questions...
 

crx2fast : thanks for the vid, it makes me feel a lot better about my setup. I'll post up more pics and vids soon.

It is all because of HMT and the beautiful things you guys do here that gave me the courage to try it myself. Thanks.

O0

Re: Just completed my 240 turbo install PICS included::
 

oh, and about the injectors, yes they are going to be upgraded to possibly the Venom 770cc units and use the SAFC to scale down. Thanks for the comments.

Re: Just completed my 240 turbo install PICS included::
 

not possible. the safc can't scale to -69 and that's what u would have to do jus to get it to idle.

Re: Just completed my 240 turbo install PICS included::
 

Nice setup looks good.I like how lots of 240 guys are getting with the program and going HMT instead of the SR20 that I think is a little overrated.Post some videos of rwd parking lot action >:D

Re: Just completed my 240 turbo install PICS included::
 

You might run into a problem with your BOV venting into the atmosphere...maybe not with the safc, but i know most MAF equipped cars don't like to idle well after you hit the gas a few times. What happens is the MAF reads the air coming in, the ecu dumps in the fuel (albeit through the safc), but when your bov pops open, you release some of the air that was metered. Now you end up with too much fuel, and not enough air just as the motor comes back down to idle. Otherwise looks nice...i wanna see some vids cause i'm thinking of picking up a 240 to do this kind of setup to.

Re: Just completed my 240 turbo install PICS included::
 

quite true.

can those motors use the MAF as blow through? that would solve that problem

Re: Just completed my 240 turbo install PICS included::
 

yes they can, most guys like the blowthrough setup when venting to open atmosphere but u need as much straight pipe on each side of the maf as possible when doing blowthrough.

Re: Just completed my 240 turbo install PICS included::
 

That is a big turbo, gotta love a 2.4 liter O0

Re: Just completed my 240 turbo install PICS included::
 

is anyone else chiming in on the fact that he wants to use injectors to big that the afc can't scale?

Re: Just completed my 240 turbo install PICS included::
 

i am a ka-t guy myself and here is my input. your spark plug wires will melt and eventually start to fail, likewise with the mass airflow sensor. i would use a section of pipe and mount the mass airflowmeter and airfilter in your ds fenderwell. and use a thick well made heat shield around the turbo as well as fasten the plug wires out of the way. i goty my car to run pretty well venting to the atmosphere and i am not running blowthrough with my z32 mass. blowthrough seems pretty risky to me with all the shock and tourque on the intercooler pipes esspecially in my car i would go through the trouble of making it map before i used a blowthrough setup. as for injectors i am running dsm blue tops i wired through an 88-91 crx si resistor box, i am making 350 whp plenty rich and could give it more fuel and up the boost.your turbo is too big , its ok tho you can switch it out when you can , i would use a t3 to4e or even better yet a garret .63/.60 (i ran one for a while it was pretty intense). alltogether if this is your first turbo setup i give you credit , i would just consider changing some things to make it reliable and drivable before you take it out. good job , send a pm if you have any truble.

Re: Just completed my 240 turbo install PICS included::
 

Attachment 37674 Attachment 37675

Re: Just completed my 240 turbo install PICS included::
 

hey kill,

Nice setup man. I don't think I'll actually run 770cc injectors. I didn't even know you could make the DSM 450cc's fit into the existing fuel rail without modification. That's a great idea and a cheap solution. 350whp, man I would love to have that in this car. The exhaust was being finished up the the muffler shop today and I'm picking up tomorrow morning and then tuning. I was wondering if you were running the SAFC2. I'm setting up the deceleration air feature which is supposed to work with the open bov. This is my first turbo setup on a 240 and I'm quite proud of the final result. Sure, there are some final things to be addressed but I had fun with the build.

I'll probably PM you with some questions. Thanks for the offer of help. I was wondering, I have to run the stock injectors right now until I pick up a set - any recommendations on the settings of the afc so I can see just a little boost - probably not over 5psi for now; the car will be babied with the boost until everything is sorted out.

EJ

Re: Just completed my 240 turbo install PICS included::
 

at a point like this the best decision would be to us sr20det injectors (370cc) stock are 270s at least untill you get new ones. i dont know how many sr powered cars there are around you but that would be a good quality makeshift mod untill you get some bigger ones. i would run 550s 14psi and tune, you will piss yourself laughing the first time that back end kicks out unexpectedly when you nail it. honda will never touch ka tourque ;)

Re: Just completed my 240 turbo install PICS included::
 

KA-T for the win!

If you are running anything bigger than 370's, look into some timing control. The bigger your injectors are (the more you have to compensate), then the more advanced your timing will be I think.

Re: Just completed my 240 turbo install PICS included::
 

i was gonna mention the 450's wont work for him unless he converts to topfeed... but i doubt his backend will kick unexpectedly with an opendiff lol. unless he got an lsd already?

Re: Just completed my 240 turbo install PICS included::
 

if im not wrong ka motors are top feed my friend jst baught a set of 460 rx7 injectors for his ka/t project and im prety sure that 450s would fit better than 460s

Re: Just completed my 240 turbo install PICS included::
 

looks great. Wish I had some time to take off to play with my car. That's what vacation is for I guess

Re: Just completed my 240 turbo install PICS included::
 

I like the idea you had for the head flange(s). Never though of doing something like that. ^-^

Re: Just completed my 240 turbo install PICS included::
 

i own a 240 as well as this guy, the dualcam came sidefeed, single cam topfeed. the 450's would work if he converted to topfeed. hope ur friend bought the right injectors for his 240.

Re: Just completed my 240 turbo install PICS included::
 

he has a twin cam and it is top feed it must have already been converted

Re: Just completed my 240 turbo install PICS included::
 

okay, here is an update:

-exhaust completed by muffler shop and now running full 3" system, downpipe and all.
-car is an LE model and already comes with a VLSD
-I'm trying to source some SR injectors but I have also found 461cc injectors available locally made by accell (brand new)
-found a small coolant leak from the turbo return line - has now been fixed.
-trying to get different fastners from the turbo to the down pipe - absolute bitch to tighten those bolts
-walbro fuel pump going in tonight
-timing has been reduced from factory 20-21 degrees to 16 degrees to ward off detonation
-ordered a really cool turbo heat shield which contains the whole exhaust turbo side within.
-new plug wires and colder plugs have been ordered

still working on trying to get the maf and filter in the fender well to avoid all that damn heat.

Thanks for all the feed back. I was wondering if anyone knows the formula for the SAFC2 settings that I have to figure out when the new injectors arrive.

EJ

Re: Just completed my 240 turbo install PICS included::
 

why do you keep insisting he's topfeed. or are you talkin about ur friend?

if this guy was topfeed why would he be ordering some sr injectors?

the formula for new injector sizeing is

[(old injector size / new injector size)-1] *100

these were suggested to me with using sr20 370cc injectors...


"for 370's, set everything to -27 (both high and low maps), For super-safety do a gradual rise from -27 to say, -5 on the high map from low rpm to high rpm"

Re: Just completed my 240 turbo install and have some questions...
 

you gotta remember about how much hotrex's setup sucked.

of course it didnt spin, manifold was warped to a choice 4psi wastegate....

Re: Just completed my 240 turbo install PICS included::
 

Okay, here's another update:

So, after everything, got the damn exhaust finished up and there was still a stupid leak. Everything was as good as I could get it but found the culprit.....the damn manifold on runners 2 & 3 were about 3 mm shorter than 1 & 4. I ran the car anyway and was able to make 5 psi. Holy ----, did the boost come on hard and fast!! It was like a point and shoot scenario and the boost only comes on about 4000rpm - not too bad considering the size of this turbo. I got that turbo heat shield kit and it is pretty wicked. Everything has been finalized using new Iridium Spark plugs, increased the timing to 18 degrees BTDC. I can't wait to get this thing finished.

More to follow with pics and vids.

EJ

Re: Just completed my 240 turbo install PICS included::
 

personally, i just use regular ole electrode NGK's. cheap and they work fine. Just FYI

Re: Just completed my 240 turbo install PICS included::
 

SO.....

Car is finally finished and came across a whole set of problems:

-runners 2 & 3 on the manifold were about 3 mm short of the other two and cost $150 to machine it flat - the absolute last time I make a manifold with individual flanges but it is perfect right now.
-oil line gave me some problems and had to be modified because it was hitting the hood and started to leak.
-found a small oil sweat on the rear of the valve cover gasket - easy fix


So the car runs perfectly and the wastegate is set to 5psi for now. After the manifold was fixed the turbo spins at idle now and it spools up really quick - boost come on at about 3000rpm. This car is deadly on the street because it is very quiet until you hear the turbo spool up and the blow off. We had a bit of fun with a couple of cars already and smoked a porsche quite badly. Took it on the freeway and holy ---- - hang on is all I can say. I can't wait to turn up the boost. I bought Iridium spark plugs and will eventually get an oil cooler, separate relay system for the fuel pump, bigger and better plug wires. This has been a blast and I will take some vids of the car in action when I have a chance. Still looking for SR20 injectors so I can feel a little better about the fuel system.

Thanks again for all the help and advice - will keep you all posted!!

EJ O0

Re: Just completed my 240 turbo install PICS included::
 

"all i can say is hold on" til u top out in 4th gear =x

and man o man are u brave running any psi with nothing for management. go buy ur sr injectors already or help me find some bigger ones for a decent price n ill sell u mine.

Re: Just completed my 240 turbo install PICS included::
 

nice work, i like the looks and craftsmenship in both those cars ;), could you use that MAF sensor right at the Throttle body so it only reads what is goin in ??? to solve those idle problems?

Re: Just completed my 240 turbo install PICS included::
 

doubt it, blow through setup requires atleast 6 inches on each side of the maf for a proper reading.

Re: Just completed my 240 turbo install PICS included::
 

turboda6,

what do you mean brave because I have no fuel management - I have a walbro 255 high-pressure in tank and an safc2 adjusted accordingly using a wideband to make sure things are good for now. It is being babied for now till the damn injectors come in. It really runs clean and strong - no leaks, timing brought back to 17 BTDC, no check engine lights and moisture at the tailpipe. Overall, pretty clean. I understand your concern and the injectors are on the way. Car has all it's smog equipment hooked up except for the EGR but it has been tuned adequately to prevent and check engine lights. I even got the Decel. air working properly having the blowoff vent to atmosphere without any stalling - it took a lot of minor adjustments but the car is very reliable.

thanks for the feedback everyone.

More pics and vid's to come.

EJ

Re: Just completed my 240 turbo install PICS included::
 

i say brave because the stock injectors have no room to compensate for boost when there already set to run pretty maxed out N/A. u add boost n the injectors try to pump more fuel they can't give... yeah u got an fpr, yeah u got a fuel pump. but the pump can't give more fuel then the injectors will give out... but if u say its safely tuned then so be it. injectors are jus something i wouldn't do without.