McCoy's turbo project part 3

After 2 months of being out of the garage due to a back injury and 1 month of craziness at work I'm now able to get back into the garage again... and just in time to get the car into the storage unit :(.

Since I'm not in a rush anymore... I was trying to get the car back together for several track days in Aug/Sept/Oct which didn't happen, I decided to go back to the topmount setup that I had first started at the beginning of the year. I took last friday off to do some cutting/welding and parts running, and over the last few days got a fair bit done.

Mocked things up on this last Friday to make the final cuts for the dump pipe. I was also going to make a new hot pipe, but found with a few cuts of the chopsaw that the T25 ebay piping I already had worked just fine.
http://www.prmsg.org/albums/album106/T3_nov09_01.sized.jpg

Gotta love the local welder... wouldn't even charge me for welding the dump pipe... said I had to bring them something more challanging to make it worth charging, lol. The JGS400 bov mounted, still need to clean up the cuts and do some bead rolling later this week.
http://www.prmsg.org/albums/album106/T3_nov09_04.sized.jpg

DP from JGS all wrapped up.
http://www.prmsg.org/albums/album106/T3_nov09_08.sized.jpg

The JWT filter was to big for the new location for a whole $12 shipped I got this new ebay filter with a 3" inlet that mated up to the aluminum MAF adapter I had laying around.
http://www.prmsg.org/albums/album106/T3_nov09_07.sized.jpg

JGS manifold bolted up.
http://www.prmsg.org/albums/album106/T3_nov09_02.sized.jpg

An older JGS400 WG and dump bolted up.
http://www.prmsg.org/albums/album106/T3_nov09_09.sized.jpg

I'm currently working on moving PS resevour and having issues with the 3/8th hose fitting, need to use some heat tonight I guess. Intake pipe is going to be REALLY short, so I need to get some 3", 90 degree piping that has a pretty tight radius on it. For now I'll run the BOV open, unless I can find a way to route the return line that doesn't require to much work.

nice pics..be sure to stretch out before working on her

Got a little more done last night. That 3/8th hose is a bear to get on the PS resevour... I had to resort to heating up the hose and it still was a b*tch.
http://www.prmsg.org/albums/album106/T3_nov09_10.sized.jpg

I did bend the smaller barb inwards some to help fitment, but overall I'm happy with it.
http://www.prmsg.org/albums/album106/T3_nov09_11.sized.jpg

Looking good...

Another late night...

Added some insulation/heat barrier for the PSR lines.
http://www.prmsg.org/albums/album106/T3_nov09_12.sized.jpg

Finished up the water lines...
http://www.prmsg.org/albums/album106/T3_nov09_13.sized.jpg

Routing/mounting the oil feed.
http://www.prmsg.org/albums/album106/T3_nov09_14.sized.jpg

Borrowed this tonight to bead roll the pipes that I've been cutting... nice to have friends with tools :).
http://www.prmsg.org/albums/album106/T3_nov09_15.sized.jpg

sweet tool!

Even with that downpipe wrapped, will you have to worry about heat issues for the Brake fluid reservoir??

Even with that downpipe wrapped, will you have to worry about heat issues for the Brake fluid reservoir??
I'm not done yet... I have a heat shield for the BMC yet to install. And I still need to pick up a turbo blanket to, now thinking about heat.

Last nights activities!

I love that bead roller... I spent more time locking it down on the vice than I did rolling beads :). I will go back tonight and use a little grease this time to get the bead alittle bigger.
http://www.prmsg.org/albums/album106/T3_nov09_16.sized.jpg

5 minutes later... it may not look pretty, but it will get the job done.
http://www.prmsg.org/albums/album106/T3_nov09_17.sized.jpg

I also spent some time cleaning up the pipes after cutting them and reattached the IM with all new gaskets.

Once I get the turbo inlet pipe cut and a few bungs welded on it (tomorrow hopefully), I can finally finish this up and drop the car off the jack stands... 3 months later!

http://www.prmsg.org/albums/album106/T3_nov09_11.sized.jpg
I'm curious why you had to move the PS resevoir. Was it for turbo piping clearance? Mine is still in the OE location without issue but then again I'm not using the same manifold, turbo etc.

Jim, I was just uploading the pictures from the weekend when you posted this question. JGS puts the turbo a little further forward and down than most log manifold setups, I like how he did it, more room to work around the turbo and not so close to the BMC. The the only downside is that you really can't point the compressor outlet down like I've seen alot of topmount setups. So, as you can see in the picture below the 45 off the compressor is right where the PSR usually sits.

Final test fitment before having the intake pipe welded and a bung added to it (in th next 1-2 hours). I used a 45' bend I had laying around, cut at an angle on one end and will weld on a short straight piece to turn this into a tight radius 90' bend to get my intake where I need it.
http://www.prmsg.org/albums/album106/T3_nov09_19.sized.jpg

Started to bolt things up over the weekend to. I'm waiting on the new intake pipe before I go any further tonight. Alll that is left to do now is bolt it back together, so I'm hoping for a Wed night startup.

http://www.prmsg.org/albums/album106/T3_nov09_18.sized.jpg

Bump for a great project on the Palouse!

Almost ready to start... I just need to finish burping the coolant, throw in the ECU and battery, and give her a turn.


The mostly finished product... will be replacing a few of the older couplers and clamps that I found in the garage during this build, add a 45 degree oil return fitting, the oem catch can and a bit more heat shielding for the hoses once I know the car is running.
http://www.prmsg.org/albums/album106/T3_nov09_20.jpg

http://www.prmsg.org/albums/album106/T3_nov09_21.jpg

http://www.prmsg.org/albums/album106/T3_nov09_22.jpg

She started on the first try last night... sounded a little grumpy at first and the lifters are louder than I expected, but vacuum looks good and idled just fine. I guess I should have expected it from a motor that's sat for nearly 6 years in a garage.

Hopefully I'll be able to take the car out tonight for a test drive once I get some more distilled water to top off the radiator.

Snow melted off enough last night that I could safely take the car out. Set the TPS, tried to set timing/idle but am having a high idle condition right now that I haven't tracked down yet... probably a vacuum leak somewhere I haven't found. Need to build a boost tester :).

Found the really bad exhaust leak too... it was related to the 02 sensor laying on the work bench, lol.

Did several pulls through the gears at 7-8psi, boy does the car scoot for only this much boost! When the WG opens, boy do things get loud... louder than I thought, maybe consider a muffler to quite it down some.

Next on the list is nailing down whatever vacuum leak I have to get the idle set right. Hook up the LC-1 Wideband and then swapping over to the correct ECU and nismo 740cc injectors and start logging some numbers as I bump up the boost.

I FINALLY got around to installing the Nismo 740cc injectors that I've had laying on the shelf since the beginning of this year. They came in a B13 sentra fuel rail and I wasn't in the mood to swap the injectors to the S13 rail, so just modified the sentra fuel rail to work :). Also swapped out the eproms in the Calum ECU to the 8.5:1 CR setup from a friend... all seems good on the start afterwards too.
http://www.sr20forum.com/gallery/data/959/nismo_740_injectors.jpg

One last shot now that I got most everything under the hood wrapped up for the most part.
http://www.sr20forum.com/gallery/data/959/engine_shot_nov_18th.jpg