Toyota GR86, 86, FR-S and Subaru BRZ Forum & Owners Community - FT86CLUB - - 86FLY - Australian Custom Turbo Jetkit 4.0 Build + Custom Flex Fuel Dyno Tune

This is the most stock photo I have of the car, with only these mods listed:
http://i1375.photobucket.com/albums/...g?t=1413556306

* Full LED Upgrade (Interior, Boot, Numberplate etc) Including Daytime Running Lights. I really didn't like the stock DRL that came with the car. These helped modernise the car greatly and gave it a sharper look.
* Xenon Headlights for a pure white beam of direct light. Brilliant true colours at night and they look cool too!
* Genuine Toyota Arm Rest from the UK. A great mod that makes the car much more comfortable and user friendly.
* Whiteline Adjustable Sway Bars - Front + Rear. Hands down the best bang for buck handling mod you can do to your 86.
* Cusco Carbon Fibre Strut Braces - Front + Rear. They help with handling and look cool too.
* Plastidip Toyota Emblems - Front + Rear. Cause, moar stealth!
* Sound Tube Delete - Blocked up the engine sound tube with the cigarette lighter cover from the glovebox (yes, there's one in there if you didn't already know!). Instant smile worthy. Great mod and it's free.
* Beatsonic Sharkfin Antenna - Version 2. I like the V2 better, it's bigger and more refined in design.
* Tinted Windows - Super dark including strip across top of windscreen. Yep, race car!
* Raceseng Ashiko Gear Knob - CNC'd in beautiful stainless steel, this little beauty weighs a huge 735 grams. This makes shifting a pleasure and a lot easier.

Initially, the whole reason I decided to buy the 86 in the first place was when I saw a fellow Aussie's amazing build right here on this forum. It blew my mind because of the power he was making, the originality of it all, the superb quality involved and I really liked the styling as well. As soon as I saw it, I decided that the 86 was the car for me! His name is Kalen and you can see his build thread here:

http://www.ft86club.com/forums/showt...ighlight=jet86

And although the video is old and the setup has changed quite a bit since (much less lag now and much more power) the video that made me fall in love with his kit is here (listen to that sexy turbo spool! Pre-supercharger!):

[ame="https://www.youtube.com/watch?v=zWxmNwV-RSs&index=1&list=FLyHXO8oWzo7JbCAgsYQW1VA"]Jet86 before adding the supercharger - YouTube[/ame]

Luckily for me, we live pretty close to each other, and, even luckier, he had just started his own company (Forged Performance Australia - http://www.forgedperformance.com.au/ ) supplying custom variations of his very own signature Jetkit! It was meant to be!

OK, so after many discussions with Kalen, we decided to begin the build on the 13.10.2014. After about a 6 week wait, the custom flex fuel tune at Tunehouse was coming up in 10 days and I really didn't want to wait another 6 weeks if I missed it! The race was on to get the build done in time for the tune.

I arrived at the Forged Performance workshop and Kalen got stuck into work straight away. The first thing to do was to remove
the entire current exhaust setup including the Revworks UEL headers and the Perrin Cat Back exhaust. These items were already sold to eagerly awaiting people to collect.

**INSERT PICS HERE**

Next, the gearbox had to be dropped out of the car so we could get to the clutch and flywheel. I've chosen to go with the Australian made Xtreme Cushioned Button clutch and an Xtreme light weight chrome-moly flywheel. The clutch will be able to hold the amount of power I'm going to be throwing at it and it will also have a lot more bite compared to the stock clutch that is too light for my liking. The lightened flywheel will help with engine responsiveness.

http://i1375.photobucket.com/albums/...psb5e25520.jpg
http://i1375.photobucket.com/albums/...psc8fb812e.jpg

Up next was to replace the stock oil sump with a Full Blown Motorsports sump. This sump has a 50% higher capacity than OEM and includes baffles to help prevent oil starvation. This sump also has a fitting port in it for the turbo oil drain. Kalen also put on one of his nice red 86 magnetic sump plugs.

http://i1375.photobucket.com/albums/...ps7f3488b4.jpg
http://i1375.photobucket.com/albums/...pse30c7d25.jpg
http://i1375.photobucket.com/albums/...pse4760c1c.jpg

Now that the sump was in, one of my most favourite and important parts of the kit was to go in next. The turbo manifold. This equal length manifold was designed and hand fabricated by Forged Performance. It's made of 304 stainless steel, it has steam-pipe construction, Billet flanges, a CNC cut merge collector and is equal to less than 1%! The design is so simple and effective as the more equal length these headers are, the more efficient the engine will be. I don't know of any turbo manifold in the world that is at this level! :)

http://i1375.photobucket.com/albums/...psd217a415.jpg

The wastegate in the kit is a 40mm Turbosmart CompGate. These are the highest quality wastegates on the market and are used in most high end drag cars, time attack cars and drift cars. Here it with the new wastegate merge setup from Forged Performance. This design allows for perfect gas flow and maximum strength!

http://i1375.photobucket.com/albums/...ps099d2b1b.jpg

Here they are on the car, perfect fit, symmetrical and right in the centre of the car:
http://i1375.photobucket.com/albums/...psd5b31fa9.jpg
http://i1375.photobucket.com/albums/...psc87fe671.jpg

The intercooler that comes with the kit is designed by Forged Performance and manufactured by the world famous Hypertune! It's very lightweight, super sexy, crazy efficient and a perfect fitment. The car really comes to life with this mounted!

http://i1375.photobucket.com/albums/...ps4e75c38a.jpg
http://i1375.photobucket.com/albums/...psdd37a79a.jpg
http://i1375.photobucket.com/albums/...ps9200c444.jpg

I've selected to go with one of the new AVO (another Australian company) Oil coolers designed specifically for the 86 with a front mount intercooler. These come with a fiberglass airduct to guide in air from the front, next to the intercooler. Here it is in position:

http://i1375.photobucket.com/albums/...ps67a7d182.jpg

And with the air duct installed:

http://i1375.photobucket.com/albums/...ps468bed28.jpg
http://i1375.photobucket.com/albums/...ps273242b5.jpg

I've also opted to go with an AVO full 3 inch turbo back exhaust. I must thank Lee from AVO for rushing the delivery in time for the build and for also meeting my requests for the tips to be in stainless steel instead of their standard titanium finish.

http://i1375.photobucket.com/albums/...psd63b0bda.jpg
http://i1375.photobucket.com/albums/...ps4f4176d3.jpg

The 3" overpipe comes with a ceramic coating. For install the engine needs to be jacked up quite high (completely off the engine mounts) to fit. Here it is compared to the stock overpipe:

http://i1375.photobucket.com/albums/...ps63ce966d.jpg

Here's it is all fitted:

http://i1375.photobucket.com/albums/...psde690981.jpg
http://i1375.photobucket.com/albums/...ps23be461e.jpg

As I mentioned, this kit is custom. Not only have I had a choice of the parts going into it, not only has Kalen hand fabricated the turbo manifold, but Kalen is also hand fabricating ALL of the intercooler piping too! He's using aluminium piping, measuring, cutting and welding all personally. Here's, a few pics of the process...
http://i1375.photobucket.com/albums/...ps254283a0.jpg
http://i1375.photobucket.com/albums/...ps9b5bd63e.jpg

The blowoff valve is again, the best available in the world. It's a 38mm Dual Port Turbosmart. These blow off valves are the highest flowing blow off valves on the market and can be switched between fully atmospheric, fully recirculation and 50/50. Great for getting passed through engineering as you can totally block it off so the setup is fully recirculating, then, after engineering is complete, you can easily switch it to vent to atmosphere for a bit of flutter if you like! ;)

http://i1375.photobucket.com/albums/...psc80feed8.jpg

All of the silicon connectors used in Jetkit 4.0 are top of the line Turbosmart. I've chosen to go with Blue:

http://i1375.photobucket.com/albums/...ps6d7923be.jpg

The kit includes a monster sized K&N Air Filter. In this photo you can see it and where it will be mounted:

http://i1375.photobucket.com/albums/...psfaed4626.jpg

Now, finally it was time to install the turbo! With guidance from Kalen, I've chosen to go for the new ball bearing, water and oil cooled Garrett GTX2867R. For ultimate spool time, weight and space saving I chose the Garrett housing over the Tial.
http://i1375.photobucket.com/albums/...ps1322fae5.jpg
http://i1375.photobucket.com/albums/...ps5f6bd298.jpg
http://i1375.photobucket.com/albums/...ps633d0d46.jpg

As soon as the turbo was installed, we just had to start it!
[ame="https://www.youtube.com/watch?v=zWviIDj1svs"]https://www.youtube.com/watch?v=zWviIDj1svs[/ame]

The dump pipe has been made and as you can see, the wastegate has be plumbed back into the dump pipe for engineering purposes. Here's a pic of the beautiful setup just before all the plumbing has been sent to the coaters :)

http://i1375.photobucket.com/albums/...ps7bc15668.jpg

.................................................. ...........................
The build is still in process and won't be done for a while longer, but, for those wanting a sneak peak of the current state the cars in, I leave you with this photo:
http://i1375.photobucket.com/albums/...psfe1b017a.jpg

Pls be patient with me as I will only be able to update this as I have time. I will get to it again asap
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