The ULITMATE* DIY sohc turbo buildup (many pics)
 

* not really the ultimate but more than you'd normally see =)

Ok...
So i've finally started on the re-turbo'ing of my car the "HONDA OF FURY" HOF for short; my friend's nicknamed the car that so it's stuck.
I bought my 90 civic si 2 years ago in february with a -----ass greddy toy 15g turbo kit and an ailing D16A6 and an hf four speed. The guy that owned the car was a total idiot and the car desperatly needed saving. At this point in my life i was paying people to tighten the belts on my other car; i knew about cars but had 0 experience working on them or modifying them. So i did what I always do and jumped in head first =)
The car stayed pretty much d16a6/greddy kit for a while while i played with the efi and did some other things to it and then finaly trashed the motor. Skip a few botched motor rebuilds and other such shenanigans and we have my current setup.

PARTS LIST (off the top of my head):
-Built D16Z6 SOHC VTEC - 8.5:1 SRP pistons; Eagle H-beam rods; ACL bearings; ARP hardware; Endyn block posting studs; ARP head studs; oe mls gasket; stock head/valvetrain/cam
-Full obd1 electronics - chipped/vtec enabled P06 ecu running crome pro
-Home built ram-horn manifold somewhat equal length; better than a log;
-Garrett T3/T04E .63ar stg3 turbine; .5ar 57 trim compressor rebuilt
-knockoff 35mm wastegate (maybe two as I have two in case i run into boost control issues)
-JRC 6" Intercooler (24x6x3 core)
-HKS SSQV knockoff bov
-2.5" aluminumized charge piping
-450cc injectors - stock ignition
-J&S Ultrasafeguard for knock control
-Techedge 2AO wideband with LD02 display wired to the ecu for tuning purposes
-Greddy profec B spec 2 EBC
-Full autometer gauge set (boost; oil press; water temp; afr (sucks but its there))
-Ebay short shifter
-Tokiko allumina or whatever adjustable shocks on all 4 corners
-intrax springs set to way too ------ low
-Jim Bob joe whoever's ebay front camber kit (hey it works) going to use the rear camber washer mod fix soon to fix camber in the rear
-15x6.5" bronze rota slipstreams in bronze withYokahama AVS ES100 tires (very nice tires btw)

To be installed in the very near future:
-Rebuilt Civic cable transmission (DX trim with higher final drive)
-8lb flywheel and better clutch (as soon as the rebuilt trans goes in most likely)
-Apexi AVC-R uber boost controller to replace the spec 2
-Aluminum EG twin core half radiator
-3" open downpipe

The motor has roughly 5000 miles on it since i built it and was tuned by myself using crome and more recently crome pro. I used it as a daily driver with the low compression built motor because I had to. I had spent the last few months hoarding parts; buying and selling ---- saving spending and getting all the stuff needed to fabricate my turbo kit. And this last week that's what I did. I put the kit together finally =)

Here is the car after we got it running after i bought it; a6 and greddy kit; not much to see
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Finally after living with the panda-ae86 wannabe paint job for as long as i could I decided i'd paint it flat black... So i did.. in my shop over a weekend a few months ago.
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

The finished product after i painted the ---- wheels that came with the car bronze. I was shopping around for rotas and couldn't decide what color; my friend kept pushing me to get bronze so i thought i'd see what it looked like. Turned out great; i liked the color.
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

I wound up getting the bronze slips and they look great
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg


Now on the to the fabrication of the turbo kit.
I took these
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

This
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Started making this
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

And came up with this
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
Say what you will about the welds but they fall on deaf ears. I have maybe 2hrs of experience behind a mig gun and I think it turned out great. The welds are holding; no leaks no cracks yet and penetration was adequate on enough of the manifold that I think shey'll hold great. Not bad for something that cost less than ONE ------- TENTH the price of a full-ripoff manifold.

After it was together i threw it in the car and it's freakin huge; there is no way i can use my stock EF rad. oops...
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Oh well; next I mount the intercooler
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Next comes the piping; easiest part of the whole build.
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg

Finally i threw together a temporary downpipe until I can get an aftermarket x-member and mount the wg on the manifold and run a 3" downpipe. It kinda leaks since i haven't been able to belt sand the flange flat after welding. I dont really care; its only temporary.
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg
http://www.we-todd-did-racing.com/we...ZkMzF5NTQx.jpg


The car runs fantastically; i'm only pushing 5psi at the moment while i make sure everything is running right and there are no mechanical problems. Above 4500 when that turbo wakes up the car makes all kinds of happy noises and just shoots forward 70 takes no time at all to hit and 2nd and 3rd gear pulls are insane.

My exhaust is only abou 12" of 2.5" pipe and it sounds spectacular; it's not hardly as loud as I thought it would be as far as engine noises; on the other hand that turbo just SCREAMS; I couldn't have asked for a better sound. I'm absolutely in love.

There are still a few things left to do; I need to plasma cut my bumper support so the intercooler doesn't sit crooked; find a way to make a hood fit with an ek half rad and clean up the engine bay. Also my spare tranny is being rebuilt and as soon as it's done the engine and everything will be pulled out; i'll paint the bay to match the car and install a beefy clutch/flywheel and probably some bigger injectors. Thats to come in the next few months.


Overall I am EXTREMLY happy with how well this build turned out. The motor is running strong; the turbo is spinning and tuning is going without a hitch. I expect to be putting down 300+ WHP in the near future!

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

that paint job turned out hella good! I'm thinking of doing the same thing to my Saturn.

Nice setup too, good luck with hitting 300whp! ;)

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

That's the funkiest rad hose I've ever seen. ;D

300WHP or bust 8)

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

yea it sucks; the one i had was too short so i had to reuse the ricerhose that came with the car.

and thanks sinister; the paint turned out a lot better than i expected too. and its still holding up. the bumper is scratched up because i've had it off like 3x since i painted it adn the passenger door got hit with a shopping cart but other than that its holding fine.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

Any special tips on painting it?

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

prep it right and use a good gun; thats all i can say

i'm lucky as i've had afriend that worked for a body shop; i used his old clear gun and what little experience i gained helping him out.

Basically what i did was sand down some bigger uneven spots (where the ricer paint before had the 2-tone ---- laid on top of the white); scuffed up the rest of the paint with a 3m scuff pad (you have to scuff the ---- out of it or the paint wont stick); used a homemade tack pad to get all the dirt and dust off; degreased it with some pre-paint cleaner; then put about 2.8 coats of paint on (ran out on the roof so thats why i say it was 2.8 :p so now i have a splotch on the roof but it works)

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

Gotta love the radiator hose. I think that's gansta yo O0 !

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

That's pretty cool. Good job on the ramhorn style manifold. That BOV is gay though. You should put a RFL on there. Matter of fact........I have one I'll trade ya for it, straight up. ;) ;D Nice job man!!!


JP

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

for fitting the 1/2 radiator what i did is cut the stock bottow radiator support were it drops in the length of the 1/2 radiator

then i used stock radiator hose on top and bottom, the top will need to be trimmed about 1-2 inches

as for your hood closing get two washers and take off your hood latch then put the washers between the hood the the hood latch the extra millimeter spacing should allow for your hood to close

hope this helps

i will try to post pics asap

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

well the half rad doesnt even go down far enough to get near the bottom support on the rad; unless i put the bottom cock below the front x-member it'll hit the hood by a lot

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

The radiator mount
Radiator hoses
Mismatched spark plug wires
half the AC still installed
Goofy fabbed driver mount
and the missing timing covers makes this a total HMT setup. Looks like lots of loose ends to take care of, but the turbokit looks real good man.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

most of that a/c ---- is gone now
radiator hoses are probably there to stay; they work
the plug wire is there because napa wires suck and fall apart
and that driver mount owns your face :p

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

why the bov way down there?and why did you space out the runners so much on the manifold?and no collector?

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

bov is as close to the turbo as i could get it; right where i wanted it; runners just wound up like that; and are you retarded? there is a collector on there

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

oops in the 13th pic down it didnt look like there was a collector.i dont understand why you put the bov on that part tho instead of up closer to the tb.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

i like the external wg off of the internal wg hole. i've told people to do that but they don't understand. pictures make the difference.

great job on the setup. post some more pics when the loose ends are tied.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

the air doesn't have to go thru the i/c keeping it that much cooler and there is more hotter air than on the cold side so it makes more noise supposedly...
I dunno if i can vouche for that; i can barely hear that ssqv over my dp when i let off but i'm also only pushing 5psi; it should scream at 12 in the next few days

some guy on h-t said it worked better than the wg off the collector; i'd like to see some more info on that.
And i plan on posting more pics of the 100% finished project :)

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

I assume since you put the wastegate there you also ported the port on the exhaust housing to match? because in stock its only about 20ish mm.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

i cut a 1 and 1/4" hole in the flange with a big bit at my old work on their press and there was maybe 1/16" of cast iron showing around the edge when i lined it up; the hole is off but the bigger hole on the flange doesn't overlap the flapper hole.

I haven't ported it out but i guess i could; never really thought of that honestly

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

ComputerJLT,
what kind of total timing are you running on 8.5:1 compression??
and if you are running more timming is it through out the whole map or just in boost portion?
i'm just curious because i recently put together a low comp set up that consist of VX slugs/Z6 which yeilds the same compression your running. i just want to get an idea of what people are running.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

actually i've had to pull a SHITLOAD of timing from this motor.
Somethign is not right with my setup but it still makes power; something is out of sync in the distro because i've had to scoot my timing columss over about 4 for whatever reason; i'm thinking the b16 tb may be ------- me up not sure. After scooting the colums over i've had to pull maybe and aditional 4-8 degrees of timing out of the maps to keep away detonation. It used to be real bad like ic ould hear it and the J&S was going nuts pulling 20 degrees of timing from at least one of the cylinders but it was still detonating. Also my distro is clocked almost all the way retarded.

Something is definately not right; thats why i've only got the nerve to go up to 5psi. and i've only boosted to that maybe 5 times since i put this together....

I've either got some wierd electrical s hit going on in my distributor; that J&S is ------- things up or i've somehow developed a shitload of carbon buildup in that engine after 5k mostly highway miles on a semi-tuned map (took another guys z6 map he had tuned for 450's and lower compression) afr's were not bad and as soon as i pulled extra timing it ran great

I'm going to bypass the safeguard and borrow a friends obd1 distributor in the next week or so and see if thats my problem. That is currently on my to do list and i've been looking into it and such... my fear is that buildup in the cylinders is causing this. Because with my low compression i shouldnt be PULLING timing i should be adding the crap out of it :-/

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

bump because this car is insane fater some tuning :Drool:

5psi is 10x faster than that piece of ---- greddy kit at 12psi... .no comparison...

i'm having CLUTCH slippage problems now... thats awesome! mm i cant wait till i fix the exhaust leaks and push 8-10

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

Why such the mad HMT style motor mount? Just toss a 88-91 mount on it and it'll make it sit correctly. Gotta give you credit on it though. That ---- is awesome.

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

very nice :) is that an egt bung way back by the o2? isn't that a bit far back for egt? i'm going to drill/tap my manifold for egt right in the collector
Also is that a real tial or a knockoff? and what is that substance coming out of the flange? rtv?

guess i didnt put that in here or you can't read ;).... The bolt holes on that mount on that motor are stripped. I bought the motor with one stripped as i guess the car was crashed and it got pulled out. drilled/retapped it and held for a while; then i guess that bolt worked its way out and the other did too. So now i have 2 stripped bolt holes :( I'm waiting till i pull the motor out to re-drill and re-tapp both holes so i can run a stock mount. that plate steel bracket is just so my motor wont fall out :)

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

watup man sick job on ur kit, listen i got the same wastegate as you, does ur spin freely at all, cuz mine seems like its loos one the flange to the manifold, and i can spin it around with my hand, duno if its missing something, and i think its causing a boost problem?

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

hmm; thats not right; no nothing spins freely :-/

i have an extra one that i'll sell u with a 1 bar spring in it for cheap. It doesn't have the fire ring but does have the flanges

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

wat size is it, and how many psi is the spring at

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

35mm and 1 bar (14.7psi) but u can put your spring in there

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

have you checked your timing belt to see if its off by a tooth?

Re: The ULITMATE* DIY sohc turbo buildup (many pics)
 

its dead on; i'm guessing the distro is off or something; it's running fine reguardless; 8psi pulls like hell