Is300 Turbo Build - Nissan 240SX Forums
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post #1 of 30 Old 08-29-2009, 03:09 PM Thread Starter
 
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Is300 Turbo Build

So this summer I was hired by a shop out in Frederick, MD called PFS and I decided that I would turbo my car by the end of the summer, before I went back to school. My power goal is 350whp (manual w55 transmission).

So here is the run down of the build.


Engine:
2.5mm headgasket
ARP Headstuds
a nice "cleaning"

Turbo "kit":
To4e 60 trim .70 hot side with v-band
hard line oil drain
Tial 50mm BOV
Tial 38mm wastegate
x02 racing (ebay) manifold
x02 racing intercooler
custom intercooler piping
used my boss' IS downpipe jig to make the down pipe
3'' exhaust
RPS max pressure plate with 6 puck disk

Engine management:
Pro-efi 48 pin
5 bar map
fuel pressure sensor
pro-efi boost controller
440cc RC injectors
Walbro 255

I started work on the car back on the 6th of August and had been working about 5-6 days a week on it. I pulled the engine to do the headgasket and clutch and had the engine back in and all bolted down and then started work on the oil lines and fabing and mocking up the intercooler and the piping. After that I started working on the downpipe with the jig, and had my boss give me a crash course on TIG welding stainless. Once I got the downpipe all welded up and the wastegate flange, and dump tube all welded up I tried my hand at Al TIG welding on the intercooler pipes (my first few previous attempts weren't so good but after doing the stainless i got the hand of using the TIG welder). It took me about a week to get the fab work completed on my car since the first couple of welds took me about an hour each. Long story short I had everything bolted down last friday. And then wired up the Pro-efi on monday.

Since no IS300 has run the pro-efi 48 I had to wait around for Jason from Pro-efi to get a base map set up and work out the trigger pattern. The attempts my boss and I had to run the 48 all failed so he is currently letting me borrow his 128 just so I can use my daily driver to get to and from school which starts on monday. Hopefully Jason can figure out what is wrong with the 48 trigger pattern so I can get it on the dyno.

Last night as I had the car running and was about to pull it out of the shop so Ray could do some street tuning to make it driveable we heard a loud "POP" and found that the exhaust I fab'ed up put way too much tension on the v-band flange on the turbo and after it heated up a little it just snapped right off (not the v-band clamp but the flange that was welded onto the turbo actually broke off). So i spent all day today cleaning up the downpipe and I put in a flex pipe on the exhaust so it won't happen again. Still have an exhaust leak though at the v-band... and my boss was kind enough to reweld my turbo.

Pictures to come when i get the car home.

Ram Rod Racing

"Dude I can't hear you, I'm in a lexus i'll call you back later"
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post #2 of 30 Old 08-29-2009, 03:12 PM
 
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No one cares. I want to see and hear it.

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post #3 of 30 Old 08-29-2009, 04:20 PM
 
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Quote:
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then nut all over it and shove it down your pathetic throat and laugh at u when u gag and die slowly u piece of shit.
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post #4 of 30 Old 08-29-2009, 08:09 PM
 
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This sounds like a sick build man. You should post up everything you have from the build. I've been waiting for a good IS300 build. Those cars are absolutely phenomenal, one of my favorite cars of all time.

Oh, and I agree with these guys, WE NEED PICS!!!! d:

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well, um... i'm jimmy the intern... FROM BEYOND THE GRAVE!

*waves hands around like a zombie*
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post #5 of 30 Old 08-31-2009, 12:13 PM Thread Starter
 
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Final product:



Front Mount (failed at print screen):



Another Picture:



First couple of welds:



Al Weld (Pretty)



Al Weld (Anthony Ugly; Also failed at focusing)



Unfinished Wiring:


Ram Rod Racing

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post #6 of 30 Old 08-31-2009, 12:17 PM Thread Starter
 
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I have the progress pics on my iphone that i need to upload to photobucket

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post #7 of 30 Old 08-31-2009, 01:18 PM
 
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Those would be sick. I think you should get either: A. A heat shield for your turbo so it doesn't fuck with the intake air considering they are so close, or B: you should make a custom (or buy an aftermarket) intake plenum and reroute it like a standard turbo setup.

Regardless, this is awesome. You should get some full car shots up too. I hope this thing is slammed!

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post #8 of 30 Old 08-31-2009, 01:28 PM
 
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I took a ride in this haus the other night. Amazing car. Too bad police officers don't know the difference between compressor surge and "peeling" tires.

Ptoth... Intake Manifold for these motors are so overpriced in my mind. I think he is eventually going to fab his own up, but for the time being all he really needs is a higher rev limiter. Haha

And what does "Anthony Ugly" mean you ass?

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post #9 of 30 Old 08-31-2009, 01:32 PM Thread Starter
 
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Monster trucking like i'm ready to rally. Ha, I don't mind the stock suspension, I mean i'll need some coilovers when i get more power than 350 but i'm not tracking the car and don't mind the 5 inch gap.

And yes a turbo blanket is in the near future. But if you notice I have the air temp sensor right there so I'll be able to read exactly what those temps are when the 48 is working correctly, I'll be able to see how hot it actually is. A GTE style intake would be a great idea, but would take about a week to fab up and get running. It is definitely a possibility and is almost a must to get more than 500hp, but there isn't very much room on that side of the engine. It would be sweet putting on a q45 TB and getting rid of the DBW though. But right now my funds are very low and I'm saving for a transmission, that right now is the bottle neck. Then the bottom end, then the fuel, then the turbo, then the intake/head/cams.

I'm most likely going to keep the IS at 300-350 for the next 2-3 years till i get a full time job and can afford to have a daily driver and just throw money into the IS to make a z06 eater

Ram Rod Racing

"Dude I can't hear you, I'm in a lexus i'll call you back later"
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post #10 of 30 Old 08-31-2009, 01:33 PM Thread Starter
 
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It means you got an ugly face

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post #11 of 30 Old 08-31-2009, 01:34 PM
 
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One thing I forgot to ask you was your oil line setup. Did you run your feed line off the OEM oil pressure sending unit location??? Also for the return line... Did you weld a bung into the oil pan or get a GTE pan?

Haha also it looks like you got pretty nice at pouring coolant all over your engine bay.

P . A . T . T .


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post #12 of 30 Old 08-31-2009, 01:45 PM Thread Starter
 
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Off of the oil neck where the filter sits there are 3 sports you can jump into, you could T into where the oil pressure sensor is, or go into a "medium" size or "large" size NPT ( don't know the dash numbers, forgive me). so i went into the medium size one off the oil neck, and used a "NPT to flared line fitting". for the oil drain my boss made me a hard line off the turbo which i welded to a fitting. from the hard line i have some 3/8ths cloth line (no need for SS braided) with a pushlock fitting to the upper oil pan which i drilled and tapped with a 3/8's NPT while the engine was just a shortblock so i had the lower pan off to let the shavings fall to the ground.

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post #13 of 30 Old 08-31-2009, 02:08 PM
 
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I love this car more and more everytime I look at it. I don't think people understand the amount of natural lights I've drank in this car.

P . A . T . T .


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post #14 of 30 Old 08-31-2009, 04:48 PM
 
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I'm going to steal your glory!!














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post #15 of 30 Old 08-31-2009, 04:50 PM
 
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Now the good stuff.









And this one is for the kids


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post #16 of 30 Old 09-01-2009, 10:41 AM Thread Starter
 
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Hahahaha your awesome, thanks tony

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Quote:
Originally Posted by duballstar View Post
I love this car more and more everytime I look at it. I don't think people understand the amount of natural lights I've drank in this car.
And the amount of vagina juice you sat on

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post #18 of 30 Old 09-01-2009, 11:09 AM
 
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What are you boosting at?

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post #19 of 30 Old 09-28-2009, 07:58 PM Thread Starter
 
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About 180kpa absolute at 5500 rpm. Which is roughly 10-11psi, but at the low rpm it doesn't produce too much power. I'm going to try and get it at 8psi all the way up to 7k rpm

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post #20 of 30 Old 09-28-2009, 11:21 PM
 
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So awesome. I am going to head up to Maryland when I finish my own 240 build and we can have an I6 showdown! (No... there will be no RB here...) The swap, as of right now, is a secret d: Unfortunately this secret is in line behind school... which means you have 1 year to get this car ready! hahaha.

I hope to see more pictures and more updates soon!
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post #21 of 30 Old 09-30-2009, 09:04 AM Thread Starter
 
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I6 turbo in a 240 would destroy me. Pumped for your build. Good luck and happy wrenching

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Thanks man! I'm eagerly checking this thread every day for updates! hahaha.
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post #23 of 30 Old 10-31-2009, 11:55 PM Thread Starter
 
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R.I.P. Lily. You were fun till your front end got deeply penetrated by a tree. Pics to come

Ram Rod Racing

"Dude I can't hear you, I'm in a lexus i'll call you back later"
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post #24 of 30 Old 11-01-2009, 01:25 AM
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Ouch, what happened?


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post #25 of 30 Old 11-01-2009, 02:40 PM
 
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"Got a sport utility vehicle for extreme sports such as towing a boat, climbing mountains in the snow and smoking blunts on dubs"

Sucks it never felt 6 grand.... RIP brah

On a real note, how much for the turbo and red couplings?

P . A . T . T .


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