SpoolinShark's turbo build
 

So after 6+ years of talking about boosting my RD, I have finally gotten around to actually doing it. I have ran into numerous set backs during this process like wrecking the car, buying clutches that don't fit.. the list goes on.. But, I was able to enjoy some boost the other day after getting it tuned and it was a great feeling.



I'm currently running 15psi but that fluctuates depending on gear but I plan on getting a smaller spring with a manual boost controller. My goals for now are between 300 - 350hp on the stock block with 15psi.



Check out below for what all is going on under the hood. I'm sure I'm missing stuff and will add it as I remember.



Engine:

• Stock Beta I block
  
• Beta II head swap (mildly ported)
  
• Colt Cams Tri-flow regrinds (270° primary intake lobe, 262° secondary intake lobe and 266° exhaust cam)
  
• Air Ram intake manifold
  
• 68mm RSide throttle body
  
• Maintec turbo manifold
  
• Emusa external wastegate (15 psi spring)
  
• Big Holset H1C turbo
  
• 4an turbo oil feed
  
• 10an turbo oil drain
  
• 2.5" stainless steel downpipe
  
• 1.5" dump tube
  
• Aermotive Rising Rate FPR
  
• Bosch 1000cc EV6 style injectors
  
• on3 320lph e85 fuel pump
  
• MAF adapter weld-in flange
  
• AEM FIC with PnP harness
  
• 2.5" aluminum piping
  
• 3" thick same side vertical intercooler
  
• Greddy style knock-off blow off valve
  
• GK style full aluminum radiator
  
• Push style conversion slim fans
  

Transmission:

• Beta II trans
  
• XTD 11lb flywheel
  
• Push style clutch conversion
  
• MAXX ACT 6 puck sprung clutch (rated for ~500hp)
  
• Slave cylinder mod
  
• Custom 3an slave cylinder line
  
• Polyurethane filled front/rear mounts
  

Brakes

• XG350 dual piston calipers
  
• Kia Spectra5 drilled and slotted rotors
  
• Rear drilled and slotted rotors
  

Suspension

• KYB GR-2 struts with KYB mounts
  
• Apex 1.7 drop springs
  
• Rear strut bar (modified eBay front one)
  
• Front strut bar (needs modified to clear Air Ram)
  

Interior

• RD2 leather seat swaps
  
• Radio delete with custom gauge pod
  
• AEM Digital AFR with wideband
  
• AEM Digital Boost gauge
  
• AEM Digital Fuel Pressure gauge (To come)
  
• AEM Digital Oil Pressure gauge (To come)
  
  
  

Miscellaneous

• Power steering delete
  
• Coolant bottle relocation
  

Stay tuned for pictures of my journey through this process.



*Teaser shots*



http://i574.photobucket.com/albums/s...58474884_n.jpg





http://i574.photobucket.com/albums/s...73268120_n.jpg

That's a lot of work but congrats on the completed project! :thumbup:

Nice Build and looks like mostly high quality stuff! I'm curious what kind of power curve you have and why you chose the Holset turbo? There's MUCH better matched turbos for a stock block high compression Beta engine. :)

One of the reasons I went with the Holset is the fact that they are really good turbos and can get them for decent prices. My plan is at least 300 - 350hp on the stock block with e85 which is definitely doable. As of right now the boost doesn't really come on until around 4,500 since the current exhaust housing is a 18cm and that is roughly over a 1 a/r. I'm working on buying a 12cm housing which should bring down the spool time a good deal and is around a .70 a/r which is more manageable.



I'm compiling all of my pics from the build and will be getting them up soon!

Wowzers! Yeah a 1.0 A/R is WAY too big for the little 2.0L even with high compression. Having to buy a new housing kind of negates some of the cost savings.. ;)



350whp on E85 is definitely doable provided the FIC will actually be able to pull the ignition timing a bit on the high end. If your E85 is truly E85 and not the crap we get in Colorado then you may not need to pull any timing.. :) Just watch your EGTS!! Hopefully you have or plan to have an EGT Gauge?

That's what I told him! After messing around with used inferior turbos and replacing/rebuilding parts, you could come out way ahead by just buying a new one from the start.



I suggest E98 from a retailer when trying to push limits. Use pump E85 on a much lower "safe tune" for daily use. E85 is never very reliable out of the pump no matter where you are.

I picked up the 12cm housing so expect it to be here next week and will get it installed. As for the turbo, I paid $100 for it originally (it was rebuilt) and $250ish for the smaller exhaust housing. So $350ish for a turbo that's good for 500-600hp isn't bad.



As for the fic, right now we are pulling 1.5 degrees up top in boost but I'm wanting to go down to pulling no timing. People have done over 400hp on stock timing.



I do have an egt bung in the manifold but not using it at the moment. It wouldn't be a bad idea to use it on down the road.

Awesome build! :thumbup:

How did you settle on pulling 1.5 degrees up top? Throw darts at a timing board? lol



FYI, the EGT gauge can help alert you to conditions that will cause detonation BEFORE detonation occurs.. :)

Yup, completely random on the timing.. Ha. But we originally started off with 1.5 degrees per psi and tweaked from there.



I also come to find out that I was running a 21cm housing instead of an 18cm. So a 21cm is comparable to a 1.61 a/r and a 12cm is comparable to a .89 a/a/r. I should definitely notice a drop in spool time!