my ghetto $100 turbo build :)

CMF_frank2

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and i.ve already spent £40 of it lol
 

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CMF_frank2

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woohoomobile WROTE:

"to be intercooled? or just low boost?
Click to expand...

non I/C woohoomobile, and around 5 psi i guess, with a C/R of 10.5:1, the 3 kg flywheel and QG injectors.
the goal is to match the acceleration of an SR20 K11 between 2k and 6K rpm, with a stock ecu (and to try it out on my misses,s 1.0 too :) )
 

CMF_frank2

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Rudy WROTE:

"keen to hear updates frank
Click to expand...

we tested it out on the 11.5:1 c/r engine (very very gingerly) very loud chatter !
http://www.youtube.com/user/aelknarf?feature=mhee
and it pulled well for such a low rpm and spark retard :)
the drain into the crankcase breather will only work on a topmout turbo, it flooded with oil and i had to fit a sump spout
and the 10.5:1 engine is nearly ready to rock :)
 

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CMF_frank2

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Tyrie WROTE:

so you've got ~$39 to complete the build... good luck!
Click to expand...

spent £45 now lol (pipes from our local asian scrapyard) and i have to include the £20 QG injectors and CGA rail really, so even a boost gauge would break the budget ! (gonna have to run without one)
gotta select the right strength of piggyback actuator spring now, for the desired 5 psi
 

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CMF_Tyrie

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frank2 WROTE:

"Tyrie WROTE:

so you've got ~$39 to complete the build... good luck!"</div>

spent £45 now lol (pipes from our local asian scrapyard) and i have to include the £20 QG injectors and CG rail really, so even a boost gauge would break the budget ! (gonna have to run without one)

gotta select the right strength of piggyback actuator spring now, for the desired 5 psi
Click to expand...

lol well according to xe.com you have 30cents left in your budget
 

CMF_ToToL

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I wanna try this way!i don't understand the spring+wastegate,the wastegate open before 5 psi without the spring?or beyond?
do you think the i/c isn't worth it in this set-up?let's try a motorcycle radiator lol.
 

CMF_frank2

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ToToL WROTE:

i don't understand the spring+wastegate,the wastegate open before 5 psi without the spring?or beyond?
Click to expand...

thanks rudy :)
the spring inside the actuator pushes the rod totol, and the extra spring pulls against that inner spring
so that reduces the pressure holding the wastegate shut (and reduces the boost)
i,ve had to block the boost control pipe too, to reduce the boost even lower (i,m currently running @ about 1 psi lol)
http://tinypic.com/player.php?v=2cnb7eo&s=5
gotta try some bigger injectors next :) tho this maf rubber collar/reducer increases fueling somewhat
 

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CMF_frank2

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ok........... we,ve gone over budget and bought a cone filter and boost gauge (thanks shaggy), should,ve titled this "£100 ghetto turbo build" *doh*
currently running with an SR t/b and a cut-off GA16 maf pre turbo, and its pulling very very strongly :D
 

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CMF_frank2

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Lodo75 WROTE:

"Hahahaha that balloon!!! Epic! Love the backyard tuning! Keep up the good work!

(would love to see it on a dyno for result…)

greetz
Click to expand...

my timeslips will be more telling lodo, i have lost faith in the accuracy/legitamacy of dyno,s tbh
been tinkering with some different bosch topfeed injectors
1.0/1.4 CGA blue ones are the 164cc 0280155942
1.5/1.8 QG red ones are the 211cc 0280155940
2.0 SR (coilpack 00 - 02) grey ones are the 292cc 0280155798
and the SR20 ones are giving some nice a/f/r,s :)
here,s the gauge showing the stock ecu trying to closeloop @ idle (a tad lean if anything)
 

CMF_frank2

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the baloon proved to be very inaccurate lol, its been boosting to 20 psi + :eek:
and the actuator has proved to be a vacuum type ! (ecu controlled apparently)
so we,ve fitted a softer spring inside the actuator for the time being

that little clutch is holding up well eh ! wheelspin in 1st and 2nd on the damp road
 

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CMF_frank2

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well it lasted a week lol :D (and drank £50 of petrol !)
all 4 ringlands let go together @ about 25psi, rings and bores still fine tho
gotta give credit to the awesome det resistance to these CG,s and the resilience of the 2 x secondhand stock head gaskets and 175mm hybrid clutch and little type 41 g/box
 

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CMF_frank2

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we,ve got rid of that damn leanout/closed looping in 4th and 5th gear now (took the connecting screw from the speedo head to the ecu)
so we,ve got fuel enrichment @wot in all 5 gears at last :)
 

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CMF_frank2

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and we dropped the fuel pressure to nearly 2 bar with the 292cc SR injectors, and the fueling was exactly the same as with the 211cc QG injectors when set to the stock 3 bar (closed looping perfectly @ idle and cruise, and off the scale rich @ wot)
so i just need to rig up this oldschool mini vacuum advance mech for a proper rising rate f/p/r
 

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CMF_frank2

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thanks kyle :)

Rudy WROTE:

whats the go with them valves, I ask cause i lost #1 cylinder the other day, its not spark, will test injector 2nite, after that it will have to be compression tested to determine valve damage, I hate it when my car is sick
Click to expand...

dunno rudy, it had the same divit on the other side of the seat, and 2 divits on the valve seat too.
i usually test my compressions down our hill in 3rd gear (my tester wont reach down the plugholes lol) and there were only 3 chugs and a gap :eek:
turning the crankpulley with a socket, and the cam cover removed confirmed cyl #1 had very little compression.
i think the injectors batch fire on startup btw
 

CMF_frank2

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RTK WROTE:

"There goes your $100 turbo conversion haha
Click to expand...

probs $200 now lol, but a lot of it has gone on R & D really eh.
the main objective really is to DIY the build and to avoid a costly remap or standalone ecu.
i had fitted a 3mm pipe to induce a manifold leak so that the maf was only sensing 1/2 the air entering the engine @ idle (and fueling it to suit) and as the throttle was opened the leak/vacuum diminished and the fueling increased to suit.
it worked ok but was pretty crude tbh, but that austin mini vacuum mech has a pull of about 5kg, so when coupled to the stock fuel reg, we should be able to double the fuel pressure to 3.5 bar as soon as that boost gauge hits positive pressure
 

CMF_k11_facelift

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Have you got more info on how the mini vacuum will work, I understand that it'l increase fuel pressure under boost, presumably by exagerating the mani pressure when positive/under boost, but not sure how it fits on to the fpr in order to work. (from googling it looks like it advances the timing in a mini.)

My plan to try first was a cheap 1:1 fpr, oversized injectors, and a pipe bypassing the throttle body to increase air. Just sounds a little too crude.
But keeping economy and mpg at low revs is pretty important to my build.

Also, when are you going to be back up and running? :)
 

CMF_frank2

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aye, the mini vacuum mech retards the timing as you hit the throttle and lose the intake vacuum eh matt (and twists/rotates the dizzy baseplate)
so i need to cut a slit down the CGA f/p/r and fit a rod under the spring, so the mech will pull upwards against the spring @ low throttle.
my gauge reads 20 inches @ cruise (about 1/2 bar vacuum i believe) so i need at least 1/2 the fuel pressure for those 2 x bigger SR injectors eh.
a proper rising rate f/p/r would be ideal (4 or 6: 1 ratio) but experimenting is all part of the fun tho eh :)
 

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CMF_frank2

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we welded the fillet piece on last this time, so that the inside of the mani could be built up with weld, and shaped for a better flow (where the honda flange and stump joins the cut-off CGA mani)
new makita die grinder FTW lol :)
 

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CMF_frank2

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i could,nt open the wastegate without the help of pliers, and the styrup pump showed 20psi as it opened !
a bit less preload and an extra spring over the shaft has brought that down to 10psi now :)
and the SR20 injectors have behaved very well over this last week (same mpg, open and closed looping as it should etc)
 

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CMF_k11_facelift

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Looking good frank :)

Thanks for the illustration about the mini vacuum, think I understand what your doing now, still seems a little excessive, any thought's about a turbo diesel boost compensator(if thats even possible)?
 

CMF_frank2

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uk_facelift WROTE:

"Looking good frank :)

Thanks for the illustration about the mini vacuum, think I understand what your doing now, still seems a little excessive, any thought's about a turbo diesel boost compensator(if thats even possible)?
Click to expand...

if you mean the vacuum controlled actuator matt ? some diesels use the brake vacuum pump and reservoir to control the boost (via the ecu) so you only have to fit the pressure controlled actuator instead eh (the rod pushes out instead of pulling in) and reverse the arm too eh :)
fitted a spare oil pressure switch to the head oil gallery today, oil light goes out in miliseconds as usual (there goes another myth :d )
 

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CMF_k11_facelift

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frank2 WROTE:

"

if you mean the vacuum controlled actuator matt ? some diesels use the brake vacuum pump and reservoir to control the boost (via the ecu) so you only have to fit the pressure controlled actuator instead eh (the rod pushes out instead of pulling in) and reverse the arm too eh :)
Click to expand...

No I don't think that's what I meant, I was reading up on what people do when turboing a n/a diesel, and instead of using an aftermarket rising rate FPR, or that brake pump system thingy that i think is on modern TDIs, they fit a 'boost compensator', which adjusts the fuel pressure to suit the boost. Seems like an elaborately designed and more boost suitable FPR.
http://www.toyotadiesel.com/phpBB2/files/detail_1.jpg
Although on second thoughts diesels wouldn't be able to use a regular fpr, so it could be nonsense lol.
 

CMF_k11_facelift

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frank2 WROTE:

"i think thats for the old (pre-commonrail) injector pump matt ? so that it delivers extra fuel during boost (rather than solely via the throttle cable eh)
Click to expand...

Ah ok, so it's nothing to do with an end rail fpr, can skip past that idea then eh, be more hassle than it worth. How's the mini vacuum device coming along, you onto a winner?
 
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