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Finished my header-Pics-MORE:21 Dec.

eeaston

By eeaston,
in Engine and Performance Mods

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eeaston Newbie

eeaston

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Here she is, just have to add a couple of supports to take the stress off the tubing.  Here are a few photos partially complete and finished.

 

The turbo is an Innovative Turbo Systems unit:

T3 Stage 5 turbine .82 AR

T04E 60-1 Compressor

 

Tial 35mm Wastegate

 

 

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjIyNTUxNnM0MTNkZmQzMXk1NDE%3D.jpg

 

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjIyNTUwNnM0MTNkZmQzMXk1NDE%3D.jpg

 

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjIyNTQ5NnM0MTNkZmQzMXk1NDE%3D.jpg

 

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjIyNTQ1NnM0MTNkZmQzMXk1NDE%3D.jpg

 

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjIyNTQ2NnM0MTNkZmQzMXk1NDE%3D.jpg

 

Sorry about the fuzzy photography!  I did that to cover up my ugly welds.

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Lizzord30 Newbie

Lizzord30

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Awsome header!! Would love to see more collector pics :) Turbo looks nice to :) Also a good pic of the intake housing would be cool. BTW your waste gate is backwords LOL Not that that will make any problems should work well. What size OD is that pipe?
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eeaston Newbie

eeaston

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Thanks, Guys.

 

It fits great, the turbo sits far enough away from the head that the plugs are easily accessible, the WG might hit the ABS can if it was there, but it's not(good riddance), and the PS reservoir will have to be moved to allow room for the compressor outlet, but that was all planned.

 

Lizz-yes, the WG is on backwards and I'll change it.  I made one mistake- I welded the flange with thru holes to the header instead of the one with threaded holes.  On the WG the outlet has threads and the inlet doesn't, so without longer bolts and nuts, that's the only way it'd bolt on.  Being impatient, I bolted it on anyhow!   :)  I will switch it when I put it in the car, the bladder will get less heat mounted the other way.

 

I'll take some more pics when I get back in town- Collector, mounted in the car, etc.

 

The flanges started as 5/8" hot rolled, so by the time I surfaced them, they were a little over 1/2".

 

Oh, and 1 5/8 OD.  Kind of regretting not using 1 3/4.

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heefner Newbie

heefner

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You deff need to make some supports for that.  This months turbo magazine has an article on tubular vs cast turbo mani's.  They claim that the tubular can't support the weight of the turbo and are very prone to cracks.  the solution, add support.  Other thab that it looks good.
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eeaston Newbie

eeaston

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You deff need to make some supports for that.  This months turbo magazine has an article on tubular vs cast turbo mani's.  They claim that the tubular can't support the weight of the turbo and are very prone to cracks.  the solution, add support.  Other thab that it looks good.

 

That's a pretty broad claim(typical of the magazine industry), but it's definately a bad idea to rely on 16 GA 304 stainless.  A tubular mani made of schedule 40 steel pipe elbows or maybe even 16 GA 321 stainless might be fine, though.  Not to mention Inconel :) for the rich folks!

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heefner Newbie

heefner

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very true.  I would love to see some shots mounted in the car on the head.  I think thats almost the same turbo setup that T-racing is running. They seem very happy with ther performance. Cant wait to see numbers.
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eeaston Newbie

eeaston

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It is very similar to Lizzord's setup, just a little bigger on both sides.  I made up a little spreadsheet to estimate airflow through the engine, plotted it then superimposed the plots over a bunch of different Garrett comp maps, and the 60-1 was about the best match I could find, I'm very optomistic and I'll keep results posted.
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eeaston Newbie

eeaston

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Yeah, I ran the eaton for awhile, but I was pretty unimpressed with it at 8-10 psi, so I didn't finish the project(turbo and super in series)  I was bumping against the blower's limiting speed at 10psi and redline, so the only way to make it work the way I wanted it would be to overdrive it more to produce big boost down low, then uncouple the pulley at higher revs to save the blower.  I didn't want to add that complexity to the system, so I'm going back to just plain (big)turbo.
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jinx Newbie

jinx

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which eaton was that ? grand prix? supercoupe?

If so, I'm surprised it didn't deliver for u. Dumb question, but did u match the drive pulley diameter from the donor motor ?

 

isn't that the exact same turbo that Lizz ran for a short time ?

 

we make our own manifolds around here almost weekly. sch 40 elbows, never crack. Most of the time we just hack of the runners from the stock exhaust manifold instead of buting a flange, and build on that.

Flange is cleaner/better start tho.

I mig OR stick weld mine. Nobody hardly run logs, mostly paired runer

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eeaston Newbie

eeaston

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Shelby- Thank you kindly!

 

Jinx- Eaton M90(supercoupe.)  I don't know what size the SC crank pulley is, since it's a 3.8 it isn't really relevant.  I sized mine to produce 10 lbs of boost.

 

I don't think Lizzord has run this exact turbo, but he currently has a T3 StgIII .63? / T04b 60-1.  I conferred with him a fair amount while deciding on a turbo and this is what I ended up with.

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jinx Newbie

jinx

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>>"The wheel is about as large as my T3 stage 5 turbine, and mine isnt that bad of spool at all "

 

Lizzord quoted from this thread;

http://www.starquestclub.com/index.pl?boar...672378;start=35

 

ask him about the turbo he had on his car 'before' the 0.63/stgIII, and gave it back to "the shop"... probably the hifi compressor, and not the t04e tho. I was curious about the power characteristics of that very same turbo you have, and asked him in another post - DSM guys swapped back to back and complained that very same turbo spool died drastically between shifts, and lost 0.2 in the 1/4 - maybe we have the exhaust flow to negate that. Se-r guys run it but only ballbearing, still laggy on the 2.0L and their torque is weak while hp is up. Lizz actually posted he missed the 'old' turbo. He noticed that whenever the external wastegate opened the car would lunge foward with his current 0.63... maybe the 0.82/stg5 cured this.

 

yeah, your manifold looks good. welds a-ok to me too, but what do I know.. I ain't no pro

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Boosted_One Newbie

Boosted_One

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The TO4B 60-1 hi-fi with a .70 and O trim runs really well.

 

For being how much larger it is the turbo really spools well, about 13psi at 3100.

 

On mine there isn't a big diffference when the WG opens or not. Once I hit 0 psi the car starts pulling hard. I have the WG dumping to the atmosphere too.

 

There is plenty of exhaust velocity IMHO to optimize the larger turbine housings.

 

So far from ~3100 to 6000 rpms I have a solid power band. It just pulls a lot like a V8.

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eeaston Newbie

eeaston

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Here are a few pics bolted up, etc.

 

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjI3ODcxNnM0MTNkZmQzMXk1NDE%3D.jpg

Front view

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjI3ODcwNnM0MTNkZmQzMXk1NDE%3D.jpg

I HAVE to get some photo editing software!

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjI3ODcyNnM0MTNkZmQzMXk1NDE%3D.jpg

Stage 5 T3 .82AR

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjI3ODY3NnM0MTNkZmQzMXk1NDE%3D.jpg

T04E 60-1...AA battery for reference

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjI3ODY4NnM0MTNkZmQzMXk1NDE%3D.jpg

http://www.we-todd-did-racing.com/wetoddimage.wtdr/i=wMjI3ODY5NnM0MTNkZmQzMXk1NDE%3D.jpg

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Lizzord30 Newbie

Lizzord30

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I use to run a T04E 60 Trim, stage 5 exhaust .63 ar(BTW plan on installing that turbo onto the Montero once my New intake Comes. I need more higher rpms with the montero and dont mind the lack of low end, with the gears it has it spools fast and low end still isnt bad even if it was NA plus the magna will help the low end respos also and maybe give more RPMS:)) My 60-1 T04B, stage 3 exhaust .63 ar. Has awsome spool and pulles great at more or less all rpms, But like you said the diff from WOT and partial Throttal is more noticalbe once the waste gate opens.

(PS Eeaston trash your ABS ;D)

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