HomemadeTurbo - DIY Turbo Forum - TurboHF's D16a6/Volvo Turbokit HMT style (warning 56k)

Well, I had a kit that I was kinda throwing together at work, and I needed to test it out on a car, so Dustin (turbohf) let me do put this kit on his car. I had most of the kit mocked up on a D16a6 at work, but I still needed to do a few things while installed on the car.

https://www.homemadeturbo.com/turbo/volvo/mobile.jpg

This is dustins garage... I did the mobile install on this one, brang the chop saw/little welder and some tools

https://www.homemadeturbo.com/turbo/volvo/d16a6.jpg

The victim.... high milage D16a6 <in a 88hf>. (but dustin is using his existing Fuel/Spark management with this setup) Zdyne Gold SECU w/ 450cc injectors

https://www.homemadeturbo.com/turbo/volvo/turbo3.jpg

https://www.homemadeturbo.com/turbo/volvo/turbo2.jpg

https://www.homemadeturbo.com/turbo/volvo/turbo4.jpg

Using a HF manifold (ported) to a Custom 4.5 by 4.5 3/4 mild steel adapter plate, to a Volvo Turbo .42 comp / .48 ex

The turbo had "Moderate" shaft play which kinda made me worry about this setup, and if it was going to even work or not.

https://www.homemadeturbo.com/turbo/volvo/pan.jpg

I did the oil pan on the mock engine, to save time. Just a small fitting welded on the backside of the pan, with some silicone on the frontside. *Note how high the fitting is in the pan*

https://www.homemadeturbo.com/turbo/volvo/testfit.jpg

https://www.homemadeturbo.com/turbo/volvo/testfit2.jpg

Test fit looked pretty good, other than the wastegate actuator was hitting the block >:( so...................

https://www.homemadeturbo.com/turbo/volvo/spring1.jpg

https://www.homemadeturbo.com/turbo/volvo/spring2.jpg

https://www.homemadeturbo.com/turbo/volvo/spring3.jpg

This called for the spring setup, Basically removing the wastegate actuator completely and using a small spring to hold tension against the wastegate flapper, and when the turbo begins to spool it forces air out of the wastegate flapper. So the more tension, the more boost, and the less tension, the less boost. What would happen if the spring fell off? You would get no boost. So I only recommend doing these setups unless you absoultly have to. They can fluctuate boost from 2-3psi, and they are a bitch to adjust.
Just thought I would take some pics so you guys could understand it a bit more.

https://www.homemadeturbo.com/turbo/volvo/oilfeed.jpg

Moving on to the oil feed, another one alot of people have questions for. Just because this is on a "D16a6" doesnt mean this wont work on your F22 or B16a. Most hondas are setup just like this.

This is the "Low Budget" style oil feed.

1/8th BSPT to 1/8th NPT Steel fitting to -
1/8th NPT Extension 1 inch to -
1/8th NPT 3way T to
1/8th NPT 1/4 Barb & Factory Oil Pressure Sensor

https://www.homemadeturbo.com/turbo/volvo/oilfeed2.jpg

I like to throw a little silicone on all the fittings.

https://www.homemadeturbo.com/turbo/volvo/oilfeed3.jpg

You can see the extension is started in the block, be sure to get the 3way T aimed perfectly for the Barb or -an fitting you are going to use.

https://www.homemadeturbo.com/turbo/volvo/oilfeed4.jpg

Now install the 1/4 barb, or -an fitting you want to use.

https://www.homemadeturbo.com/turbo/volvo/oilfeed5.jpg

Now put the High pressure line on and clamp it down (I like to use 2 clamps) Or use -an line.. This is low budget so we are doing barb fittings with hose clamps, I have never had one fail at all. (high pressure line can be bought at NAPA) 350psi

https://www.homemadeturbo.com/turbo/volvo/oilfeed6.jpg

Route the line in front of the timing cover, but away from the drive belts.

https://www.homemadeturbo.com/turbo/volvo/oilfeed7.jpg

Most T3 turbos have a 1/8th inlet for the oil feed. I used a 45 degree extension and a 1/8th 1/4 barb (like on the back) for the inlet feed.

https://www.homemadeturbo.com/turbo/volvo/downpipe.jpg

Once the oil feed was done, I started finishing up the downpipe.

https://www.homemadeturbo.com/turbo/volvo/downpipe2.jpg

It isnt as sexy as a beau garrison downpipe, but I wanted it low budget, No mandrels.. just ---- laying around in the shop. It goes off the factory 2in DP, then straight to a "Nissan SER Spec V" 2.5 downpipe, lol. I wrapped up my ugly welds with exhaust wrap.

https://www.homemadeturbo.com/turbo/volvo/exhaust.jpg

Dustin also wanted his new exhaust installed he bought from Beau.. All 3inch, w/ a flex and 2 resonators. (no mufflers) I had to make some ghetto ass exhaust hangers, lol It will probably fall off tommorow :P

It sounded pretty good...

https://www.homemadeturbo.com/turbo/volvo/bov.jpg

Next was the charge pipes, I used a combination of some DSM pipes I had, and some Starion Braided pipes that dustin had. All about 2in (ID) Using a Factory DSM 1g BOV

https://www.homemadeturbo.com/turbo/volvo/bov2.jpg

Alot of people ask how to hook a BOV up, its really simple, run a vaccum line off the nipple of the BOV and run it to the intake manifold.

https://www.homemadeturbo.com/turbo/volvo/vact.jpg

This one was tapped into the Fuel pressure regulator line. You can see the Boost Gauge was tapped into the Fast idle port (all using 3 way splitters) you can get these at auto parts stores.

https://www.homemadeturbo.com/turbo/volvo/done.jpg

All done.. Nice, no intercooler, just some nice hot charge pipes! Came out pretty decent. The project didnt take more than 3 1/2 hours to install on the car, and about 100 bucks in materials (not including management)

The first test drive, the spring was set to 3psi (GAY!) So I told dustin how adjust the boost

https://www.homemadeturbo.com/turbo/volvo/boostadj.jpg

After dustin beat his fingers about 3 times :-X , I went ahead and bent the bracket with a large pry bar to get it set at 5-6psi.

Its still slow IMO, and is burning a little bit of oil from the exhaust side seal.. but manageable

https://www.homemadeturbo.com/turbo/volvo/volvo.jpg

Oh, and while I was in Dustins interesting neighborhood, I met this dude that had a volvo with a SB 327.. Had duel 3inch sidepipes off the fucker, god it was so loud, hahaha, I had to take a picture.

Jeff Frank