Custom Turbo Build (Twin Scrol EFR 6758)
 

Hey Everyone,

I've been slowly working on this project for quite some time and thought this may interest a few. So right off the bat I'm just going to go ahead and answer the questions I know will be asked.

Why turbo over supercharger?
Cosworth, Edelbrock, and Jackson Racing have really good offerings and I don't think I would be disappointed with any of them. BUT.. I just really like turbos. And living in CA and having this crappy 91 it is a huge benefit to me to be able to vary boost levels depending on fuel using a flex fuel setup. This isn't possible with a SC setup.

Why did I decide to go the custom route rather than just buy a kit?
There are some really good turbo kits already on the market (pTuning, Full Blown, Full-Race, MAP, etc.) however, none of them checked all of the boxes for me. The ptuing setup is close to what I want but not exactly. And in the end I also just wanted to do my own thing. Fill up those rainy days.

What are my goals?
Eventually my car will be track only but for the next couple of years it will still be my DD. Actually, I love driving this car so I am going to DD for as long as possible. In that regard I am trying to build a car capable of being regularly thrashed at the track and reliable enough to DD. Making a car fast is easy. Making it fast while remaining reliable enough to take anything thrown at it is not. Nor is it cheap unfortunately.

Am I going to build the motor?
Not yet. But eventually.

Current status:
http://i307.photobucket.com/albums/n...ps2r8mldpu.jpg
http://i307.photobucket.com/albums/n...pshvrt4pa9.jpg

Today's progress:
http://i307.photobucket.com/albums/n...psklhs22vm.jpg
http://i307.photobucket.com/albums/n...pspeo9ynz6.jpg
http://i307.photobucket.com/albums/n...psqvs4rtqg.jpg

Subbed interested to see where this goes. Good luck man

subbed! Very cool!

Well you have me intrigued. What made you decide to go with an internally gated BW EFR? From my research they have shown to be very hard to modulate and control boost levels.

We love to see other people using a 3d printer for prototyping, this looks pretty good so far.

Subbed as well.

Very nice, Subbed.

Nice , efr 7163 is also good

I really like the tech in the BW compared to the Garrett (Gamma-Ti wheel, ceramic bearings, stainless housing, etc.). The internal gate in the BW still isn't as good as an external gate but it's pretty damn good compared to any other internal gate. Their wastegate port design really is really awesome and if you want to nerd out on specs, design, and materials this is the turbo you pick lol. And there is absolutely no way I could package an externally gated twin scroll in this location. I plan on using a twin port wastegate actuator so hopefully that will help with the control a bit.

Just got mine a few weeks ago and I love it so far! I have random plastic parts all over my house now lol. Printed some brake ducts yesterday that bolt in as a direct replacement for the fog lights. :thumbsup:

That was at the top of my list with the mixed flow wheel. But I chickened out and went with the smaller one. I did some research but couldn't find really any good data of the 7163 vs 6758 spool times.

Subbed, I'm also in the Bay Area. Would definately want to see this when finished.

...must be nice. :(

Look forward to seeing the progress!

What model did you end up going with?

Wow that is pretty awesome! Subscribed :)

I went with the Makergear M2. Still learning the effects of the small adjustments and accounting for variances between colors/spools, but overall I'm getting some pretty good prints now.

I know the BW EFR has all that whiz bang technology. I am assuming you have seen this post:

http://www.ft86club.com/forums/showthread.php?t=99808

awesome turbo placement, Have you made a mock up exhaust manifold for it as of yet? Seems like a good area to manage heat really well.

I have not seen that. Hopefully I have better luck!

Not yet. I am going pretty slow. This is my DD so I usually end up taking it apart Friday night for measurements and test fitting, etc. Then I have to put it back together on Sunday to drive to work on Monday. I have the waterjet parts for the turbo mounts on order so as soon as I get that welded up and have a permanent mount for the turbo I can work on the header. I have a pretty good idea of what my plan is but I'll wait until I can post some pictures.

Notice anything missing?
http://i307.photobucket.com/albums/n...ps6iwidf0q.jpg

Made some room for the intercooler
http://i307.photobucket.com/albums/n...psjyxoano0.jpg

I love this!

I remedied my boost issues with a TurboSmart unit. I HIGHLY recommend picking one up for your EFR. They offer a plumb back (100% recirculation) and a dual port (50/50 recirc/BOV).

The stock rubber diaphragm is really flimsy. This replaces it with a brass piston similar to a true BOV.

Keep posting updates! Stoked for your build man.

http://i.imgur.com/u0E6msE.jpg
http://i.imgur.com/v9XXUMS.jpg
http://i.imgur.com/jDLl10v.jpg

Great setup, exactly the way I would build a turbo setup. I'd go for the 7163 though if you are going to keep the car higher compression. :)

Thanks for the info! And glad you got your issues sorted out. Planning on using the TurboSmart Kompact like you as well as the the twin port wastegate actuator (I will have a wide range of boost with flex fuel).

Got some parts in from the water jet today. Got anxious and welded my turbo bracket up right away. :burnrubber: Not perfect but not too shabby for not touching a welder in over a year!

http://i307.photobucket.com/albums/n...pscgp22cwq.jpg
http://i307.photobucket.com/albums/n...psfqiadg1t.jpg
http://i307.photobucket.com/albums/n...ps51fzjjxv.jpg

Sorry for the picture overload today. I'm just excited I finally have some real progress to show.
http://i307.photobucket.com/albums/n...psoi5vkndg.jpg
http://i307.photobucket.com/albums/n...psre62fdth.jpg

I disagree, I say MOAR PICS! :thumbsup:

Awesome build!

Just for you. Confirmation that the overpipe will fit. It's even equal length!
http://i307.photobucket.com/albums/n...psuckvlmn0.jpg
http://i307.photobucket.com/albums/n...pscgcva61p.jpg
http://i307.photobucket.com/albums/n...psbds8usgj.jpg

Now to get this thing back together and attend a super bowl party :drinking:

subbed

Working on a design for the tube to T4 flange transition. Going to have this part investment cast. Trying reduce turbulence into the compressor by having a gradual expansion through the bend rather than an abrupt transition right at the flange. This is the biggest part I've printed yet. Had a couple of instances where the print shifted a bit. I think the tension on the drive belt is just a bit too loose.

http://i307.photobucket.com/albums/n...pscvogepk7.jpg
http://i307.photobucket.com/albums/n...psorimvqov.jpg

Do you use support material?

I do. This part needed a ton of it both inside and out. Really sucked to remove it from inside the runners. I think it would successfully print without any internal supports though. Prints like this are really tempting me to upgrade to a dual extruder so I can print the supports with a water soluble material.

Great work so far! subbed along!
If you don't mind me asking. How much are you expecting this setup to cost from start to finish?

That's a good question. And one I don't really want to know the answer to :bellyroll:

But if I had to guess I would say about $10k. A lot of tool purchases and supporting mods included in this.

The main components are:
Turbo: $2,400 w/ turbosmart IWG actuator and BOV
Intercooler core: $300-500
321 stainless tubing and merge collectors: $1,100
Aluminum tubing: $300-$500

The rest is hard to add up. $50 here, $100 there an so on. So I don't really know lol.

Any updates?? :)

Sorry, not much for updates. Just got home from a nice 10 day ski trip in Colorado. Why did I have to come back home to work? Will be traveling for work the next couple of weeks as well so probably nothing new for awhile. I have been talking with a few casting companies about the above part getting quotes and design suggestions to help with the casting process. Hopefully I can finalize that soon. I did get some presents in the mail today though..

http://i307.photobucket.com/albums/n...ps3qvnb45a.jpg

Okay :(

How do you realise the oil reservoir? To be more specific - how "big" should this be? Im looking to go the same route like you but I will just mod the frontpipe with vband clamps to fit the turbo. I want to use the FA20DIT scavenge pump just like you.. Is this plug and play? We need a adaptor plate I guess - like the avo one.

I love this. Always love people who engineer their own stuff for their cars. Nice!

Sent from my LG-D850 using Tapatalk