HomemadeTurbo - DIY Turbo Forum - my junkyard setup is finally running (56k beware)

my junkyard 4agte ae86 is finally up and running

after some major Megasquirt problems 2 weeks ago(my fault), my 2-3 week 4agte project is finished .... except it took almost 10 months, (well, their is no such thing as finished). It was definitely worth it, the torque just livens this car up , I'm hear to stay The BOV sounds cool too ..

chassis : 1985 ae86
engine : 4age largeport 9.4:1 compression
turbo : IHI rhb5 (ford probe/mx-6)
intercooler : Ford Probe
BOV : bosch/porsche model
manifold : weld el log type, 1.5" tee/elbows, 1/2" flanges, egr
dumpipe : 2.5" weld el, two O2 sensor bungs, 1/2" flange
downpipe : 2.5"
catalytic : 2 3/8", 2.25" rest of exhaust
ignition : Ford EDIS, currently controlled by MSnEDIS, also have MJLJ
fuel : Megasquirt, Walbro 190lph pump, 365cc GZE injectors, stock FPR

The MS/EDIS setup is the _goods_ , started first crank, feels very smooth and OEM like.

If I ease into the pedal boost sits between 7-8 psi from ~3000 up, if I tromp on it to WOT, it'll spike to 10 psi above 4500 RPM.

please keep in mind that this is a work in progress. I just had to do a quick and dirty to get the car to the point where I could drive it, honestly I was getting tired and loosing hope, and was pretty much ready to abandon the project, so I needed to have that first drive. As it turns out the system only had a couple of minor bugs, no leaks or anything major at all, over the last week I've been driving it more and more, and have even ventured onto the freeway/401, my confidence in this car is building :)

I am temporarily using 'foil' for heat shielding until the parts go off for ceramic coating and metal shields are built over the winter ( the foil is actually working amazingly well ).

The filter/intake assembly is temporary. One weekend this summer I hope to finally get the battery in the trunk with the relocation kit I got off Q ...hmm 2years ago. I'll be making an 'air box' where the battery was located with cold inlets feeding the box from the fender and from behind the grill (where the current filter is ).

The crusty old ignition wires will be replaced this week, and I'll probably pick up one of those nice bolt-in replacement Accel coil packs over the winter.

I simply clamped the crank wheel to the ae86 crank pulley and welded it as close to center as possible. It works fine, but now that I know the 'solution' works well, I'm going to invest in a properly centered and tigged crank trigger setup, done at a machine shop.

Eventually I'm going to plumb the BOV and catch can into the intake (might have to do this to pass smog).

The crush bent downpipe is going to have to do until I replace the current turbo with the new one, which requires a slightly different flange/dump pipe arrangement ( a big fab job I don't want to tackle for a while ).

The turbo is temporary, the new one is oil cooled so I can dump all the water lines, it's also pushes slightly more air, and has a smaller lighter turbine housing made out of better casting metals.

Next weekend I'll be;
- replacing the 8 psi actuator with a 4-6 psi adjustable one to get me to more realistic levels, I'm currently just about maxing out the GZE injectors with the 10 psi spikes (80% duty cycle) which should put the car close to 200 HP at the crank, no matter how you dice it, that's probably not the best thing to do to a 3 rib.
- installing cheap ass turbo muffler to get me through smog

- installing new ignition wires
- fabbing brackets and permanently installing Megasquirt

Here's a front shot of the car;
http://members.rogers.com/neil85ae86...t_06192004.jpg

Here's a rear shot of the car;
http://members.rogers.com/neil85ae86...r_06192004.jpg

Here's a shot of engine bay;
http://members.rogers.com/neil85ae86..._front_top.jpg

Here's a shot of the front top of engine bay, you can see the crank wheel and sensor in the picture, as well as the IC piping.
http://members.rogers.com/neil85ae86...crankwheel.jpg

Here's the front corner where the AFM used to go. It shows the ghetto catch can, bosch BOV, the GZE air temp sensor in the intake piping, and that's the EDIS module that controls spark in the background.
http://members.rogers.com/neil85ae86...bov_n_edis.jpg

Here's a top shot of the turbo assembly, the 1200 degree paint is peeling ....as I knew it would, just didn't think it would be sooo messy :) A piece of black 1/4" plate blocks off the dizzy hole. The angle iron bracket coming off the dizzy plate also attaches to the bottom of the block, it takes the weight of the turbo and manifold partially from the head. Their is another bracket that is sandwiched between the PS pump and block that presses over the brass oil feed fitting to support it so that it doesn't crack ( common problem ). I had to modify the PS bracket slightly for the protruding oil sensor.
http://members.rogers.com/neil85ae86...turbo_view.jpg

Here's a shot of the junction box
http://members.rogers.com/neil85ae86...c_box_open.jpg

Here's a shot of the closed up box, which leaves access to the MS fuse incase I have an accident :)
http://members.rogers.com/neil85ae86...box_closed.jpg

Here's a temp shot of the MS, the tube is for the MAP sensor, it's amazing how long of a tube you can run before any noticeable delay in response is observed.
http://members.rogers.com/neil85ae86...ar/ms_temp.jpg

Finally, here's a shot of my ugly rotted out muffler, dynomax with rusted out internals sounds horrible.
http://members.rogers.com/neil85ae86.../ugly_muff.jpg

Neil