This is my first time doing a turbo build, and the car is my daily. So far its been a 4 month process, and I'm currently putting everything back together and trying to correct the damage done by a shop that really had no idea how to do a turbo setup on a KA, and frankly no business doing most of what they did. More on that dumb ass and his shop later... who knows I might find more things he did wrong. Most of this is just copied from my build thread on another forum. Hopefully its entertaining / helpfull to people out there doing the same shit.
And yes, I did promise strippers, blow, and slow cars street racing in another thread if this one gets sufficently awesome. So make it happen!
Car: '95 se
Setup breakdown:
Subaru 550cc side feeds (swapping clips was more of a PITA than I'd expected)
Walbro 255
Turbonetics Ball bearing T04B, .48 a/r
Turbonetics BOV, & WG
Modified Ebay S14 SR intercooler + charge piping kit
Ebay CXRacing Manifold
Custom DP
Custom exhaust
Relocated battery
Gauges: AEM wide band, autometer boost/vac, VDO water & oil temp, and a mechanical oil pressure gauge that needs to be replaced.
BikiROM for tuning; lol horray it works!!!
![Image]()
Adjustable Fuel pressure regulator - not originally planned
BC stage 2 cams - not originally planned
Down the road I'm planning on making a DIY manual boost controller, installing an adjustable FPR, re-doing the exhaust, running some race gas, and jacking boost for the occasional moment of significantly more than normal power. I also plan on an aftermarket radiator (w/ built in oil cooler if I can find one that will fit), so that the stock engine might survive a weekend or two at the track (road course for me) on low (5-7psi) boost.
**Late April**
Initial messy build pictures: (sorry about size and quality, some were taking on a cell phone that isn't mine)
Mock up of turbo and manifold to make the DP
![Image]()
Funky custom DP, 2.5'' bend out of the 2.5'' turbine outlet for clearance reasons before gong to 3'' the rest of the way.
![Image]()
Piping fitment... lowering the PS reservoir, and using a random radiator hose for the turbo outlet makes the snug fit on that side work.
![Image]()
![Image]()
Pipe coming out of the IC is mild steel exhaust pipe...
![Image]()
So is the pipe where the battery used to be.
![Image]()
The BOV flange was not welded onto the charge piping in this picture. The steel pipes have since been painted to cut down on rust issues. On the bright side, all the charge piping was bead rolled if it was trimmed, even the steel ones. The turbo's oil feed line has also been routed in a more well fitting way at this point.
** Early May **
Pictures and stuff from the weekend. Mostly just linking pictures my friends put up when they tell me about them.
Flickr Photo Download: DSC_0238
Flickr Photo Download: DSC_0237
My car is at about time 2:40 or something...
YouTube - CCVT Car Show
*Note* -- Its important to note that my Bikirom was working great by this time, but tuning it was nearly impossible because the car was running on 3 cylinders, likely because of the head being warped.
** Then school got in the way and all of a sudden it was late June **
Well, long story short, the head was warped, and cyl#2 looked to have less carbon buildup than the others. I seriously hope that was what prevented me from running on all 4. The head is back on the car, but not torqued down till I find a 12mm 12pt deep socket that clears the cam journals. -- I guess 1/2'' drive wasn't what I need, and that 3/8'' might work out better.
Cams and FPR are being added since I had it all apart. Hopefully it will help me make a bit more power out of it.
Its nice to be starting to put it all back together again, but also frustrating that I may have to wait another week or so to finish out some summer classes and find some replacement fuel lines that were too stubborn for their own good
![Image]()
I think I started this project like 4 months ago at this point... I miss having a daily.
Maybe some pictures tomorrow if the weather holds.
** Jun 27 **
Lots of pics.... Oh and I found the socket I needed at sears...
Freshly back from the machine shop... lifters dropped back in.
![Image]()
Ahh shiny aluminum...
![Image]()
Shot of BMC clearance... May be sheilding that at some point, but i figure its minor in the grand scheme of things. I like the look of the valve cover, just wish that the letters were more shiny and that it wouldn't scratch so easily.
![Image]()
Front shot... it gets kinda tight to the dizzy on the intake to the compressor. But I like shots where I can see the compressor blades.
![Image]()
And damn it... looks like I have a rats nest to deal with.
![Image]()
** Early July **
Lately I've been trying to figure out how to block off my EGR w/ shit I have sitting around my apt, how to hook up an ebay AFPR that is likley to leak anyway, replacing fuel lines, realizing my oil drain is probably not working correctly, trying to get the fuel rail back onto the upper intake mani, and sorting out some electrical issues w/ my relocated battery. There's other shit I'm trying to do on the car as well, but its kinda minor I think.
Maybe I'll make an overly long and detailed list later today.
And yes, I did promise strippers, blow, and slow cars street racing in another thread if this one gets sufficently awesome. So make it happen!
Car: '95 se
Setup breakdown:
Subaru 550cc side feeds (swapping clips was more of a PITA than I'd expected)
Walbro 255
Turbonetics Ball bearing T04B, .48 a/r
Turbonetics BOV, & WG
Modified Ebay S14 SR intercooler + charge piping kit
Ebay CXRacing Manifold
Custom DP
Custom exhaust
Relocated battery
Gauges: AEM wide band, autometer boost/vac, VDO water & oil temp, and a mechanical oil pressure gauge that needs to be replaced.
BikiROM for tuning; lol horray it works!!!
Adjustable Fuel pressure regulator - not originally planned
BC stage 2 cams - not originally planned
Down the road I'm planning on making a DIY manual boost controller, installing an adjustable FPR, re-doing the exhaust, running some race gas, and jacking boost for the occasional moment of significantly more than normal power. I also plan on an aftermarket radiator (w/ built in oil cooler if I can find one that will fit), so that the stock engine might survive a weekend or two at the track (road course for me) on low (5-7psi) boost.
**Late April**
Initial messy build pictures: (sorry about size and quality, some were taking on a cell phone that isn't mine)
Mock up of turbo and manifold to make the DP
Funky custom DP, 2.5'' bend out of the 2.5'' turbine outlet for clearance reasons before gong to 3'' the rest of the way.
Piping fitment... lowering the PS reservoir, and using a random radiator hose for the turbo outlet makes the snug fit on that side work.
Pipe coming out of the IC is mild steel exhaust pipe...
So is the pipe where the battery used to be.
The BOV flange was not welded onto the charge piping in this picture. The steel pipes have since been painted to cut down on rust issues. On the bright side, all the charge piping was bead rolled if it was trimmed, even the steel ones. The turbo's oil feed line has also been routed in a more well fitting way at this point.
** Early May **
Pictures and stuff from the weekend. Mostly just linking pictures my friends put up when they tell me about them.
Flickr Photo Download: DSC_0238
Flickr Photo Download: DSC_0237
My car is at about time 2:40 or something...
YouTube - CCVT Car Show
*Note* -- Its important to note that my Bikirom was working great by this time, but tuning it was nearly impossible because the car was running on 3 cylinders, likely because of the head being warped.
** Then school got in the way and all of a sudden it was late June **
Well, long story short, the head was warped, and cyl#2 looked to have less carbon buildup than the others. I seriously hope that was what prevented me from running on all 4. The head is back on the car, but not torqued down till I find a 12mm 12pt deep socket that clears the cam journals. -- I guess 1/2'' drive wasn't what I need, and that 3/8'' might work out better.
Cams and FPR are being added since I had it all apart. Hopefully it will help me make a bit more power out of it.
Its nice to be starting to put it all back together again, but also frustrating that I may have to wait another week or so to finish out some summer classes and find some replacement fuel lines that were too stubborn for their own good
Maybe some pictures tomorrow if the weather holds.
** Jun 27 **
Lots of pics.... Oh and I found the socket I needed at sears...
Freshly back from the machine shop... lifters dropped back in.
Ahh shiny aluminum...
Shot of BMC clearance... May be sheilding that at some point, but i figure its minor in the grand scheme of things. I like the look of the valve cover, just wish that the letters were more shiny and that it wouldn't scratch so easily.
Front shot... it gets kinda tight to the dizzy on the intake to the compressor. But I like shots where I can see the compressor blades.
And damn it... looks like I have a rats nest to deal with.
** Early July **
Lately I've been trying to figure out how to block off my EGR w/ shit I have sitting around my apt, how to hook up an ebay AFPR that is likley to leak anyway, replacing fuel lines, realizing my oil drain is probably not working correctly, trying to get the fuel rail back onto the upper intake mani, and sorting out some electrical issues w/ my relocated battery. There's other shit I'm trying to do on the car as well, but its kinda minor I think.
Maybe I'll make an overly long and detailed list later today.
