The Turbod AH Hatch!

Im getting very close to putting my turbo on my civic soon so i thought i would post it up here for you all to see/comment on and help me out.

This is the first time i have turboed a car and and doing it totaly from scratch and mostly by myself. I will be only getting a workshop to finish off the intercooler piping i cant do and the dump pipe and exhaust. And the tuning ovcourse.

My short term aim is for around 150fwkw on the stock engine while i build up a forged engine for much more power.

The parts i have soo far are:

Custom made log manifold by me
Garrett Gt2560 Turbo
AVO Bar and Plate Intercooler 540 x 200 x 76
Intercooler pipes
Blitz Supersound BOV which i have a flange for so i can make it plumb back
450cc DSM Injectors
Custom Braided Oil lines
Custom Water lines
Oil Catch Tank
Innovate LC-1 Wideband O2 Sensor
Dual Core Aluminium Radiator from a EG/EK Civic
Adaptronic Computer
3 Bar MAP Sensor
M&W Dual Pole Ignition Coils

I will be runnig it with 2 coils for a wasted spark set up as is it much easier to implement this rather than keep the original dizzy and CAS, due to the age of the engine it would of been a PITA.

PICS!!

http://www.redpepperracing.com/galle...97-1/Turbo.JPG

http://www.redpepperracing.com/galle...ntercooler.JPG

http://www.redpepperracing.com/galle.../Injectors.JPG

Intercooler mocked up on my parts car

http://www.redpepperracing.com/galle...%20Mounted.jpg

http://www.redpepperracing.com/galle...ifold%2018.jpg

And thers lots more photos here if you want to have a look.

Hope yous like it.

Cheers
Luke

nice something different hats off to you mate

Seems like youre off to a good start,

Just make sure to meet the engines thirst for fuel,

i.e. Fuel reg (sard,malpassi is good) and def a better fuel pump,

BTW- Have you paid attention to your brakes, Going fast is great and Hondas have great brakes, but damn 150fwkw, mmm... might want to chnage to atleast new dot4 brake fluid, braided lines and obviously new rotors/pads,

My advice is that aslong as you dont race its not worth it goin a big brake upgrade,

The stuff for the brakes can be had cheap and is a quite straightforward to do yourself.

it wont need a new regulator, the stock ones work fine. Im thinking about a new pump as well but have heard the stocker will last up to this power level. Im goin to be putting in a surge tank soon after its done which will get probably a bosch pump feeding from it.
At the momoent i have upgraded to standard 86 integra disc's all round and the integra master cylender as well. This is a huge upgrade from stock. and im getting slotted rotors for the front soon and endless pads.

Where's lloyd, he'd love this LOL

Good work son..

Hes seen it before and is quite impressed :)

as am i.

The quality of your work seems high!

Quote:

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Originally Posted by fat_85_civic

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Quote:

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Originally Posted by I heart the SSS

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Luke Meet Justin

Justin Meet Luke

Luke, Justin will be doing us a photoshoot once your car is done (and im looking less shabby) as he owes me

Luke glad to see you finally getting a thread on here (rather then ask 10 or so questions in relation to the build and me trying not to give anything away)

p.s Let me know when your coming up to Livo :)

Very cool. Love ya work. :thumbsup:

Hey Luke,

sounds like you got it mostly sorted.

> on the stock engine while i build up a forged engine

Are you aware of the YCP vitara pistons many of the US D16 builders are using for their
big boost builds?
It's a proven approach to big numbers and might save you a few $$$.


Those injectors look like black tops to me. However, those are better suited to 4valve heads than the blue tops.



> it wont need a new regulator, the stock ones work fine.

On the Endyn web site, theres a tip on drilling out the fuel return on the stock regulator.
Otherwise, good fuel pump and you're good to go.


Kudos on the turbo selection, not too big. Whats the hot side A/r?

Just a thought, is it too late to turn the turbo 180 degrees. In the pictured configuration,
the exhaust has to turn 180 degrees immediately after the turbine.

In the proposed configuration, you'd have a much more generous radius on that turn.




I'm interested in more info on the wasted spark ignition configuration.

Care to share the details?

Nick.

Ive seen the vitara pistons but in the D16A3 motor i have they yeild a very low compression ratio due the the much larger combustion chamber than the SOHC engines.

haha, yeah the injesctors are black tops, they flow the same as the blue tops but, i think their just from a newer engine, ill change thet now.

Im not to sure of the hot side A/R ill have a look and find out.

I really did want to have the turbo facing the other way, but there just wasnt enought room to fit everything in if it was that way. The turbo would have been a fair way out from the block due to the wastegate actuator and would of hit with the radiator, and the air filter had no where to go.

Im in a bit of a hurry at the moment but ill post up about the wasted spark a little later

Cheers
Luke

For the wasted spark set up ill be runnig these coils:

http://www.nissansilvia.com/forums/i...post&id=154338


Which are triggered by the adaptronic management system. If you stick whit the stock computer or any other form of it, i.e. Hondata, you cant do wasted spark as it needs a distrubutor to run im pretty sure.

I think it will be much easier for me to set it up and run this way rater than trying to adapt a later model dizzy to fit and then re-wireing it all.

Cheers
Luke

> yeah the injesctors are black tops, they flow the same as the blue tops

Blue tops spray in a single cone. Black tops spray in a dual cone pattern.
Otherwise same sameness.

> I've seen the vitara pistons but in the D16A3 motor i have they yeild a very low
> compression ratio due the the much larger combustion chamber

I think FJT distributors now do a longer conrod which recovers a lot of the lost compression ratio.

If you've access to a machinist, it's supposedly possible to rebush B18 rods from 21mm to 19mm piston pin. They are slightly longer than d16 rods and are another route to recover the lost compression ratio.

I THINK it may be possible to source YCP Vitara pistons with a 21mm piston pin.

YCP make Grand Vitara pistons which are 75mm, 21mm wrist pin. But it's a long time since I looked at that stuff.

nothing wrong with forged pistons though.

Nick.

will be very interested in this build, and especially the power it results in, personally i'd think 150kw to be a bit of a stretch (esp for any extended period of time) but i'd love to be proved wrong!

yeah i assume 150 will be about the upper limit on higer boost before i blow something up, i wont be running it like that everyday. And once its all running im going to start saving up to forge the bottom end and maybe sleve it if i want to have crazy power levels, we'll hve to wait an see.

Parked and waiting
http://www.redpepperracing.com/galle...C04286_001.JPG

Last time it will look like this
http://www.redpepperracing.com/galle...C04287_001.JPG

http://www.redpepperracing.com/galle...C04288_001.JPG

http://www.redpepperracing.com/galle...20DSC04290.JPG

http://www.redpepperracing.com/galle...20DSC04293.JPG

Had to shave this stud down so the dump pipe will fit on
http://www.redpepperracing.com/galle...20DSC04295.JPG

Tight fit!
http://www.redpepperracing.com/galle...20DSC04296.JPG

http://www.redpepperracing.com/galle...20DSC04297.JPG

http://www.redpepperracing.com/galle...20DSC04299.JPG

http://www.redpepperracing.com/galle...20DSC04300.JPG

Im booking if in for a dump pipe and full exhaust to be done this week and then ill wire up the computer and get it tuned.

Cheers

Luke

Yeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee eeeeeeeeeeeeeeeeeeeeeeeeeeee





































eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee ees

very very nice mate!

nice work.............

Got more done today

Put the fitting in the sump and sealed it up wiht high temp sealant
http://www.redpepperracing.com/gallery/d/239538-1/1.JPG

http://www.redpepperracing.com/gallery/d/239541-1/2.JPG

Then got the intercooler in place
http://www.redpepperracing.com/gallery/d/239544-1/3.JPG

Start of the intercooler pipes, all made out of mandrel bent aluminium.
http://www.redpepperracing.com/gallery/d/239547-1/4.JPG

http://www.redpepperracing.com/gallery/d/239550-1/5.JPG

http://www.redpepperracing.com/gallery/d/239553-1/6.JPG

http://www.redpepperracing.com/gallery/d/239556-1/7.JPG

How the filter will be postitioned, and the box is the same size as the battery im getting so its just there to make sure everything fits.
http://www.redpepperracing.com/gallery/d/239559-1/8.JPG

How I modified the black box to remove the PCV valve, ill be running this straight to my catch can. This thing is a PITA to remove as well.
http://www.redpepperracing.com/galle...39571-1/12.JPG

http://www.redpepperracing.com/galle...39568-1/11.JPG
And its off to the exhaust shop tomorow morning to get the dump pipe and exhaust made up and all the intetrcooler pipes welded up. Its getting a 2.5' mandrel bent the whole way back with a resonator and muffler.

Cheers
Luke

excellent

hell yes! AH all the way!

coolies i saw the car today, looking good!

Must-see-moar

ZC/D16 I likey!!!

I noticed the engine pictured out of the car is a brown top? - and the one in the car is a black top? The brown top is a fuel only ECU with vac dissy, would that be easier to turbo ignition wise? I ask as I have a JDM AS CRX Si with a browntop ZC is all.

Love the AH/ZC-d16 combo, the first of the true quick injected Hondas. Did you buy the car alreadsy converted or do the conversion yourself with the DOHC?

James.

Thanks guys,

JMSBND - I did the conversion myself about 3 years ago, the one in the car is a browntop, i just painted the rocker cover black as the brown was flaking off and i think the black makes it look much better in the bay.

Cheers
Luke

hell yeah this shit is rad :thumbsup:

props man :thumbsup::thumbsup::thumbsup:

Its home from the exhaust shop and looking good, ive got some pics but am too tired to put them up so ill do it later. But i got most of it all bolted up today and it starts and sounds good!
The task for the next few days is to wire up my computer and then try and get it running on that one.
Does any one have a base map that would be good to use? Im mainly after the ignition timing map as i will be able to tune the fuel with my wideband, it doesnty have to be perfect, just enought to get me to the tuners.

Cheers
LUke

I await the computer results........good to see somebody trying the d series DOHC instead of the B sreies it's different!

Quote:

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Originally Posted by JMSBND

I await the computer results........good to see somebody trying the d series DOHC instead of the B sreies it's different!

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+1

be good to see what power this yeilds..

for reference, mine is @ 165fwkw, and jon's @ 240fwkw... both built though, but be interesting to see what this pulls!

very very nice build ! cant wait to see the results !

WOOOOOHOOOOO, it runs. Not very well but its working at least.
All thats left to do is a little cleaning up and tune.

Centurius: What management are you using? Would i be able to get a copy of your map to help with the setup of my base map?

Cheers
Luke

Video Clip, plzkthx :p

hey luke do u go w'gong uni?

sure do, doing mechanical engineering. Do you go aswell??

nah i've graduated a while back now but a few months back i was picking my misses up and i was pretty sure i seen your car.
cant rem why i thought it was your car..

Quote:

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Originally Posted by fat_85_civic

WOOOOOHOOOOO, it runs. Not very well but its working at least.
All thats left to do is a little cleaning up and tune.

Centurius: What management are you using? Would i be able to get a copy of your map to help with the setup of my base map?

Cheers
Luke

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using a Stinger EMS.. don't know if the map would be much help though with all forged internals, custom grind cams and 525cc injectors...

Any updates bud?!?!

haven't done anything at all for the last few weeks but will be getting back into it this week hopefully.
By Thursday hopefully ill be ready to book it in for a tune.

WOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO OOO!!!

Just went for a drive up the street! It is flipping awesome. My base map i made seems to be working damn good and it sounds epic.

All i have to do now it put it all back together and get it tuned!

Ripper vids FTMFW!!!

Skiiiiiiiiiiids?

Got it booked in to be tuned by Shan from Adaptronic this coming Friday! I cant wait.

oh, oh, oh, can I come with you?

yeah man for sure! its booked in a mrc dyno at around 10 on friday, you free?

I am free my man.
Is it near harris park? Recon you could grab me from harris park?

wel it got tuned on friday, i was abit rushed for time so it only quickly got done and i have to take it back to be finished off. It ended up having 11psi boost and more power than i expected. It is crazy fun to drive now.

Heres the graph of when it was completely stock

http://www.redpepperracing.com/galle...Stock+Dyno.jpg

And here is the graph after tuning on friday

http://www.redpepperracing.com/galle...1/DSC00029.JPG

142.6Kwatw

its alot more that i expected and one i fix afew small things up and get it tuned again im hoping to crack 150kw

Cheers
Luke

Was awesome to be there man.

I sadly didn't get to really take video of it tuning and shit (not enough memory but didn't really seem worth it at the time)

I did take a few snaps, I'll blank out your plates first :thumbsup:

http://i426.photobucket.com/albums/p...1092009227.jpg


http://i426.photobucket.com/albums/p...1092009230.jpg


http://i426.photobucket.com/albums/p...1092009226.jpg


http://i426.photobucket.com/albums/p...1092009229.jpg

:edit: Sorry, missed the money shot.

http://i426.photobucket.com/albums/p...1092009228.jpg

wtf

what a sleeper!

cheers Lloyd for the pics. It was good finally getting to meet you on the day.

Quote:

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Originally Posted by fat_85_civic

cheers Lloyd for the pics. It was good finally getting to meet you on the day.

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All good mate, wasn't believable for others without the pics.

Was awesome to finally be able to meet you :)

Now we just need to get my shit together and get me started now

Well done!!! The car is a sleeper for sure as I saw it at MRC friday! Very neat!

is 3 bar map sensor a must have for turbo zc?
i mean do u have to put a aftermarket map sensor for boosted zc?

you have to if you want to run more then about 10 psi

I will forever regret selling my AH....

Looks good, mate!

holy crap! 140kw out of a stock engine, very impressive!
making me think i have serious changes to make to my setup to extract more power lol.

are you planning to keep it at the 150kw mark? i don't mean to sound negative, but it'd want to be a very healthy engine to be putting that sort of power through stock internals.
Would hate for it to go pop after all that work.

what are the figures? been on the 1/4mile? should do 11s i rekon

Quote:

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Originally Posted by VTi_b0i

what are the figures? been on the 1/4mile? should do 11s i rekon

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nah, maybe low 13's?

but its so light? and with 140-150kw atw thatd be 12s easy i think

thats resl nice, but putting that power to the ground?

Quote:

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Originally Posted by ALLMTR

I will forever regret selling my AH....

Looks good, mate!

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You sold it? :eek:

Quote:

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Originally Posted by Centurius

Would hate for it to go pop after all that work.

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lol, I'm sure Luke could easily put another D16a1 in :p

Quote:

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Originally Posted by VTi_b0i

what are the figures? been on the 1/4mile? should do 11s i rekon

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Quote:

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Originally Posted by VTi_b0i

but its so light? and with 140-150kw atw thatd be 12s easy i think

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Actually Christian, a D16a1 AH (well, JDM AT Civic) does 15.5 or so out of the box.

I'd say Luke could get into the 13's with ease and push further with further suspension and tyre work.

Quote:

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Originally Posted by Bludger

thats resl nice, but putting that power to the ground?

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Yep, atw Bau.

have enough trouble with b18cr in the crx.

Buy an AH Bau :p

sorry to spam, but out of all the old honda's I like......


crx gen 1 & 2

accord 86 - 91

da & dc

some civics

I'll have a DA1 soon :wave:

PDATE Wooooooooooooo

I haven't really done much since i had the quick tune done a few months ago. I know im lazy. But im going to get back to it!

I wasn't to happy to be running 11psi boost everyday, so i bought a different actuator and installed it and now it is at a nice safe 6psi. I will try to hook up the boost solenoid before the next tune.

Ive also been playing around with the computer and the tune. The main feature of the Adaptronic computer is that it tunes its self as you drive around, using my LC-1 Wideband. The AFR is pretty much perfect for light throttle and cruising and the fuel economy is slowly getting much better.

i know, its not much to have done in about 4 months but i do have some plans which i am going to do very soon. Alot of them are going to be getting it ready to be engineered so its all legal.

I am trying to get a hold of a b20 dizzy out of a 3g prelude so i can remove the individual coils. SINISTR tried this set up but never finished it before changing dizzys again. I have thought of a way im pretty sure will make this dizzy work perfectly. If it all works out removing the coils and putting the dizzy back will make it look much more stock. . Im doing this for2 reasons:

I am going to go a more stealth look in the engine bay while i get it engineered. Ive had a few run ins with the cops and only luckily have i not got in trouble.

The CAS set up i have at the moment is not very good. I removed the 4 toothed wheel and replaced it with a 32 toothed wheel (i think) this works fine is exactly what the computer wants, but the 32 tooth wheel is larger in diameter, probably by about 5mm. This prevents the top of the CAS being put back on. The b20 dizzy has this wheel inside already so i can remove the CAS totaly.

The throttle cable has become quite sticky and will not press smoothly. I have taken it out and lubed it before and it only lasted a while. I am going to have a custom cable made as Honda do not make them anymore.

I am making a enclosure for the pod, to stop it sucking in engine bay heat and also for legal purposes, I have made a template up out of card board and will be taking it somewhere to be bent up out of aluminum. What thickness would be good for strength and heat shielding?

Im thinking about doing the EF Gauge Cluster Swap to get VSS. This would allow me to use some more of the features in the ECU, like WOT shifting, launch control, and different boost in each gear.

Due to using the carby tank still when i got down to about a 1/4 of a tank, i start to get fuel surge around hard corners getting wire the lower it gets. Does a Si pickup fit in this tank? If it does i will get one of them or if not ill be installing a surge tank and another pump soon, hopefully before its tuned next to.

Ive bought some new 15" rims, i just bought them as they were cheap and i want to get some good tyres in 15". Ill most likely change them later. They were painted a dodgy gunmetal color when i got them and im now in the process of painting them black, i think they should look good.

Hopefully im buying an 18mm Whiteline sway bar sway bar for the rear. Its made for an EK (14mm) civic, which is the same in design as and EM1 (16mm), or an EG (14mm) and DC2R (22mm) but the last two have different end links. This way i can easily go up or down to 22mm or 16mm or 14mm by just changing bars.

I have also bought a set of TEINS, and will be getting 24mm T-bars to go with them. What rate rear springs would be good? Im thinking 4's with this rear sway bar or maybe 5kg's? its my DD but i ride my bike most places, i got enjoy a hard drive through the hills so this is what im mainly after.


I should have more updates coming in more frequently now. And ill try to get all the new pics up soon!


Cheers
Luke

I finnaly got around to installing my TEIN's, 24mm T-bars, 19mm front swaybar, Davids Bumpsteer correction Kit, and my new slotted rotors. All i can say is WOW! The difference is amazing! It feels so so good. And i get much better traction now due to the stiffer rear.

All i need now is an adjustable panhard rod to centre the axle and i can put my new rims on with some sticky tyres and ill be set. I would put them on now but there is no way they wont rub on the left teh position the axle is in at the moment.

PICS

Stock vs TEIN's
http://www.redpepperracing.com/galle...5_1024x768.jpg

New Upgrade Motoring Torsion Bars
http://www.redpepperracing.com/galle...5_1024x768.jpg

19mm Integra Swaybar and Cleaned up subframe
http://www.redpepperracing.com/galle...6_1024x768.jpg

Ready to go in
http://www.redpepperracing.com/galle...0_1024x768.jpg

Bumpsteer Kit plus sealing boots to keep dirt and water out of them
http://www.redpepperracing.com/galle...3_1024x768.jpg

All Installed, still need to paint the caliper and wheel well
http://www.redpepperracing.com/galle...8_1024x768.jpg

Stock Rear
http://www.redpepperracing.com/galle...2_1024x768.jpg

New TEIN's and you can see my 18mm swaybar for the rear in the background too
http://www.redpepperracing.com/galle...7_1024x768.jpg

Comparison... TEIN's are much shorter
http://www.redpepperracing.com/galle...9_1024x768.jpg

Only photo i have of them instaled after the camera died
http://www.redpepperracing.com/galle...0_1024x768.jpg

Today i just installed the IM off a D16A8 to make the engine bay look alot neater and also installed a Moroso Breather tank soI can get it all engineered soon. Ive been working alot on this over the last few week and will put up some more updates tomorrow.

Cheers
Luke

I'm so so so very jealous Luke but I'm happy to see it finally happen for you!!!!


lol, glad to see my suspension :p (still considering other bits and pieces seeing as what My car shall enjoy soon), hopefully I don't have to do a complete cleanover like you did bro

Hey mate probably a dumb question, but where abouts did you get the torsion bars from and how much PM me if you dont wanna say in the thread :) i must say awesome build thread so far ;)

This is awesome :)

respect!

Quote:

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Originally Posted by GUIL7Y

Hey mate probably a dumb question, but where abouts did you get the torsion bars from and how much PM me if you dont wanna say in the thread :) i must say awesome build thread so far ;)

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I got them from here http://www.heeltoeauto.com/Torsion-Bar-Hondas-c-53.html. Hopefully ill be buying some camber plates from there soon too with the dollar the way it is.

I just bought some S2000 callipers from America to go on. they bolt straight up and use 11" or 280mm disks. I cant wait, it should stop good then!

I have a week off between uni and starting my new job soon so im going to try and get my rear sway bar installed.

this is coooool!!!