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Old 01-23-2008, 07:17 PM   #26
polarisman14
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Default Re: Budget Turbo Build... From the ground up

Sorry man, made me think of beerfest there...

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Either way good luck with it, you can make 300whp on a stock head it's just that the head is the limiting factor (along with intake manifold, I'd pick up a 2000 one and port the runner openings and tb, ported stock tb) so it'll take more pressure and probably more heat to do so, at which point you can damage the engine. Make sure to include a wideband and a EGT probe/gauge on your list.
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Old 01-23-2008, 08:59 PM   #27
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Default Re: Budget Turbo Build... From the ground up

well.. my great day just got better.... no more turbo....

in the process of removing the exhaust housing for proper cleaning... the main shaft SHEARED IN HALF! i mean come on... i had soaked it in oil and i was tapping downward on the exhaust housing... the housing came off and what came off with it was half of the main shaft and the exhaust impeller....

o well... more to add to the list i guess

-AcId-
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Old 01-23-2008, 09:07 PM   #28
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Default Re: Budget Turbo Build... From the ground up

again spend the money on a good turbo, a head swap can be done any time later on. DON'T try and port your head your self porting is a art and if u don't know what your doing u will HURT power not make it and just hogging out the port will do nothing for u but slow the air flow. most of the power from porting will be made around the valves. just take the stock head your getting to a good shop in your area or have mcnews or Karl do a port job for u. over 300 has been made on a STOCK zetec by more than one person. So just think with better parts and a small port job 300 will not be hard to see
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Old 01-23-2008, 10:31 PM   #29
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Default Re: Budget Turbo Build... From the ground up

well... i'll have two heads... and i have done port work before... and no... i dont plan on changing any shapes or anything like that of the ports... just cleaning them up and smoothing out the machine marks... and yeah... ive also done valve work before aswell...

i dont know... we'll see what happends...

but now.... it looks like the money i would have spent on a cyl. head... will go towards the turbo i wanted in the first place....

now the only question....

I know the GT28RS can flow 350-360whp... now... i'm not needing that... im wanting tops of 310-315whp... so what compressor should i run? should i stick w/ the "disco potato" or go with a step smaller for faster spool up?

im not the best w/ compressor maps... ive tried to figure em' out a few times with no luck... perhaps its time to try again.

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Old 01-23-2008, 10:38 PM   #30
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Default Re: Budget Turbo Build... From the ground up

As I understand it the GT28R may be a little better suited for your application but I believe the RS is a ball bearing turbo and the R isn't. Please correct me if I'm wrong.

I also know that different compressor/turbine wheels and housings can affect the max power output of the turbo so you may want to look into a smaller turbine housing, porting and polishing the ports on the compressor and turbine side, ceramic coating the turbine housing, or maybe different stages of compressor/turbine wheels.

Any combination of these things, plus using heat wrap and ceramic coating on the other exhaust components, will help reduce the spool times to varying degrees and produce different peak HP levels at different rpms.
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Old 01-23-2008, 11:13 PM   #31
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Default Re: Budget Turbo Build... From the ground up

well... what about the GT2560R? it looks half way decent also...

and it looks like all of the mid framed turbo's in the GT series are ball-bearing... which i would prefer to stick with....

any suggestions anyone?

-AcId-
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Old 01-24-2008, 05:16 PM   #32
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Default Re: Budget Turbo Build... From the ground up

All GT series are BB, im pretty sure. So the 28R is BB. The gt25 is only good for like 250 crank accroding to Garrett..iirc. So that would put you at right over 200 to the wheels.
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Old 01-24-2008, 05:21 PM   #33
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Default Re: Budget Turbo Build... From the ground up

well.. the smaller frame 25's arnt oddly enough...

as for turbo choice... looks like i'll just be going for the 2860RS... that way if i ever feel the need... i have a little room to grow.... and from what ive seen power wise on boost... i dont think i'll need a full 18psi to hit 300whp... but i could be wrong... ive got a head coming now... couldnt beat $75 shipped.... so once the bottom end gets balanced, i'll start on the head... light clean up... 3 or 5angle valve job (which would work out best?) and bolt it on....

thanks guys... i'll keep u alls updated as things progress

-AcId-
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Old 01-24-2008, 08:23 PM   #34
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Default Re: Budget Turbo Build... From the ground up

The 5 angle should work better because the point is to produce something that follows the contour of the valve seat as closely as possible. It produces a better seal. It's generally more expensive, though.
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Old 01-25-2008, 11:40 AM   #35
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Default Re: Budget Turbo Build... From the ground up

Hey polarisman,

I am from Nashua, NH!

My turbo build is starting this week!

I am getting dynoed in Concord, maybe we could work out a dyno day together. It seems you have a mail-order tune? correct me if i am wrong.

Its great to finally see a boosted zetec in my home state.

*edit*
I was just looking at your setup. FMIC!!

We'll have to have a showdown this spring!

Last edited by apotropaic : 01-25-2008 at 11:54 AM.
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Old 01-25-2008, 01:57 PM   #36
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Default Re: Budget Turbo Build... From the ground up

I would see the price diffrence between a 3 and 5 becuase i dont theink it will make a diffrence. The zetec head can only have so much improvment with out casiting a completely diffrent design. I would go for the 3 if its a few hunderd or even a hundred cheaper and sit there. I would guess that 18 will put your right at 300 witht he zetec head and lower compression unless you mill the head. I would just go with 28rs as far as a turbo goes...it will get over 300 and thats good enough for a focus as a dd..and considering your using stock svt pistons i wouldnt push any higher anyways. And i just looked all GT series are BB.
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Old 01-25-2008, 06:41 PM   #37
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Default Re: Budget Turbo Build... From the ground up

Glad to see you are in NH and getting into the focus scene. I am having my built engine put in my car right now so my car is not able to make it to the dyno day. It's actually a front mounted heat exchanger, the intercooler itself is a barrel-style air-to-water intercooler.
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Old 01-26-2008, 12:03 AM   #38
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Default Re: Budget Turbo Build... From the ground up

cyl. head is on the way.... its comming fully dressed w/ the stock cams... buckets... and everything... the head has around 55k on the clock... and was removed for install of a cnc'd head... shipping was a little higher so i ended up having to give $90... but hey... i'll do the 3 angle valve job... i'll clean up the ports.... perhaps new springs (doubt i'll need em though...) and i plan on a light bead blasting of the outer surfaces once the head is bare (which i'll do at work...) to make things nice n' pretty.... so i'd say... i'll prolly end up with around 250 in the head and it will suposively fit my needs....

i hope to have some pic. updates soon... we shall see what happends.

thanks guys
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Old 01-26-2008, 06:59 PM   #39
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Default Re: Budget Turbo Build... From the ground up

just found out that I may have another foci coming my way for next to nothing... its got a new motor and the only issue with it is its been curbed so it has some front susp. damage... perhaps a part out... hopefully its got a 5spd so i wont need to build a tranny... either way.. it should be fun

-AcId-
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Old 01-26-2008, 11:09 PM   #40
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Default Re: Budget Turbo Build... From the ground up

Ive got a turbo off a 5.7 diesel you can have.

you might be able to squeeze out some boost at about 5 grand in 4th.
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Old 01-27-2008, 05:38 AM   #41
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Default Re: Budget Turbo Build... From the ground up

holset what?!
some merkur guys use those big diesel turbos.
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Old 01-27-2008, 02:15 PM   #42
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Default Re: Budget Turbo Build... From the ground up

really? ouch. Thats a big ass turbo.
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Old 01-28-2008, 11:44 AM   #43
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Default Re: Budget Turbo Build... From the ground up

It is, but I guess it spools quickly for its size. I'm happy with my tiny T3 for now
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Old 02-05-2008, 06:43 PM   #44
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Default Re: Budget Turbo Build... From the ground up

A few updates....

my cyl. head will be here tommorrow and i'll be taking it to work and trying out our new steam tank on it... so pics of that hopefully thursday...

and i got a few more pieces together....

I plan on building my manifold tommorow or thursday while at work....



All pieces are stainless...



right at 1.625 I.D. and a nice solid 1/8" wall...





and the turbo outlet flange will be made from this chunk of .500 thick stainless...

and the best part is... it was all free... left over pieces we had at work my boss said i could have... and a good friend of mine from work who is a certified welder is gonna piece it together for me free of charge aswell... all i gotta do is cut the pieces... cut the flanges... and he'll weld it up... so hopefully all will be together soon...

im not sure about the head flange though... i can make a new one... or i can cut the one from the stock manifold i have laying around off... and bore it out to the I.D. of my new piping... weld it up and call it done... would save me a lot of time....

anyways... thanks
-AcId-
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Old 02-06-2008, 06:18 PM   #45
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Default Re: Budget Turbo Build... From the ground up

well... started on the manifold... just have to make the turbo flange and exit... and smooth the rest of it out....



some of the welds are smoothed out...



gonna open up the exhaust ports and make them nice and flush... I did end up using the stock manifold flange... i'll just have to take it and have the manifold plained when im finished...



and my head came today...



pretty complete for $90



and for giggles...



tell me what ya think so far....

and can someone help me out w/ the location for the manifold dump/turboflange? ive seen quite a few different variants and dont know which route to go...

thanks

-AcId-

-UPDATE-
smoothed out the rest of the welds today... and started on the dump/turbo inlet piece... should have this manifold finished by tommorow... and i steam tanked the head while i was at it.... so very little cleaning will need be done before i start my port work...

here's the pics...








i cut out the turbo flange as well... its not perfect... but it'll do... no pics of it yet... i'll post up the finished piece tommorrow...

Thanks
-AcId-
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Last edited by AcIdBuRn02ZTS : 02-07-2008 at 06:58 PM.
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Old 02-08-2008, 02:39 PM   #46
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Default Re: Budget Turbo Build... From the ground up

I <3 this thread.

That manifold is super nice, ESPECIALLY for free! Good work, bro!
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Old 02-08-2008, 03:04 PM   #47
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Default Re: Budget Turbo Build... From the ground up

I would do the GT28RS (GT2860R) I can tell you from first hand experience how its gonna do..... freakin awsome.


FWIW I have a couple of Holset's too.... one of them is on the truck and the other is going to be an experiment this summer.
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Old 02-08-2008, 03:41 PM   #48
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Default Re: Budget Turbo Build... From the ground up

ah, that manifold was looking pretty nice until I saw that homemade neck for the turbo flange, lol
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Old 02-08-2008, 06:53 PM   #49
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Looks a little rough, but hey...for homebrew, yowza!

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