OK, When the boost kicks in, it feels great. But it seems to take forever!

Here is my setup:
D16y8
BMC tubular mani
Down2Turbo T3 "super 60"
Deltagate
vafc / rc440
dsm gen1 bov
boostcoolers "spearco" intercooler
2.5" chargepipes
2.5" downpipe

Here is my problem:
I don't have any boost below about 3000 rpm, and full boost doesn't come on until around red-line in the first three gears. Before today I was maxing out at around 7.5 - 8 psi in 1st thru 3rd. I'm not sure what my deltagate was set at, but I assumed that was it. I was running an open downpipe at the time. What surprised me is the fact that it didn't boost at all at lower rpms, or more than ~1-2 psi in 4th, and less in 5th, when the rpms never get very high. I was guessing it was because the rpms were too low and it wasn't creating enough exhaust flow to spool the turbo. But this isn't normal (boosting so late, and not at all in higher gears), is it?

Ok, so tonight I bought a flange and welded it to some 2.5" pipe so I could complete my dp with a flex section which I then bolted to the stock exhaust. Now, it starts to spool at around the same time - ~4000 rpm, but it only gets up to around 5-5.5psi before topping out at redline. Don't get me wrong, 5.5 psi feels great compared to stock, but I need more!!! I know this can't be normal. What do you think it is?

One other thing, I tried threading a brass plug into the "vacuum" hole at the top of the deltagate, thinking this would be the same as installing a mbc set for infinitely high boost (am I right?) and hoping this might help it to spool faster and higher, but it didn't seem to have any effect at all.

Only thing I can think of is exhaust leak (I don't hear anything tho?), or wastegate problem. Think this is it, or anything else?

HELP

 

vac leak possibly are all your charge pipes clamped down nice and tight? double check it all cause more than likely thats what it is

 

dayum das a big *** turbo for a d16

 

So how is the WG hooked up right now? Exhaust leaks before the turbo? BOV stuck open?
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stock exhaust isnt helpin you too much either.

do you have an air filter on the turbo?

 

T3 super 60 is kinda big for a D16. There are a few tuning tricks that can be done to help you spool but they should be left to people with llots of experience. What are you doing for engine management by the way? Do you have EGT on the car? How about access to a wideband?

-Michael

 

super 60 is perfect for a d16...thats what im gonna beusing and my friend has one on his car. fast as ----. two of my friends are using huge t3/t4 turbos on their h22 and b16 and those things spool a lot quicker than you would think

 

ya'll are crazy. The super 60 T3 is just fine for a D16. It can reach full boost on a D16 (6-8 psi) before 4k for sure. You could put a T3/T04 on a D16 that will spool up faster than his is doing now.

His problem is that damn stock exhaust. He has a 2.5" downpipe that bottlenecks to a stock exhaust. Can you say super back pressure? downgrading to 2" charge pipes would probably help a bit too. I'm willing to bet he also has a minor vacuum leak as well.

Deltagate wastegates suck ***, fyi.

 

I used a socket on the charge pipes instead of a screwdriver when I put them on, so they should be good and tight. I also jbweld beaded them to make sure.

The turbo is a .48 a/r on the turbine side, and I don't think it should be too big. I plotted it on a compressor map before selecting it and it seemed great 10 - 20 psi. I wanted to get something that wouldn't be boosting all the time, and would leave me some headroom in case I decide to build an engine. I know some other people are using this turbo with no problems.

I know the stock exhaust isn't the best, but I couldn't spool very well before the exhaust went on, and I know some other people run it without a problem like that.

Right now, the WG and bov are both hooked up to the vac line for the cruise. I'm using the "boost" hole in the side of the deltagate.

I'm only using a boost gauge for now, but I retarded the timing a little, and I'm using the afc, so I should be fine for more than 5 psi. I can hear NO detonation. I don't understand how a wideband or egt could help diagnose a spool problem tho?

I'm using a k&n filter.

I assume it must be leaking somewhere, or I've got a faulty turbo, wg, or bov. I'm hoping it is just a leak. I guess what I need to know is: how do I tell if I've got a vac leak, charge leak, or exhaust leak without a dyno? It isn't like I can watch them while I'm boosting.

And how do I know if the bov isn't working?
I've got a plate I can use to block off the wastegate, so I can test to see if it is leaking.
Not sure how to test the turbo tho.
Actually, I did forget to put on the new gasket on the head when I installed the exh manifold, so maybe that will help?