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My BL T67dbb single turbo install project


Homer
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There seems to be a little bit of interest in documenting a budget single conversion using the XS power kit, so here goes :) This isn't a thread for technical, more of a 'project' thread so feel free to comment, ask questions or point out where I've inevitably done something dumb ;)

 

 

Firstly, a little background:

After nearly 3 years of ownership and BPU its time for an upgrade. Though the car is running perfectly its now of never to go single, after being in a few single turbo cars there's just nothing on earth that compares to the power (and sound :D ), I've just got to have it!

 

I was in two minds which direction to go for the conversion, there were two main contenders:- The full BL kit and install from Vortex (full cost would probably around £4.5k) or go for an XS Power kit and install from Turbofit (Probably around £2.5k).

 

After a few weeks of hunting around I figured screw it I'll install it myself :Pling: This opened the door to build a higher spec setup for the same price as the XS Power install. The XS Power turbo kits from the states are incredible value for money so decided on this as good start point. For some reason I've always liked the sound of the T67 so this formed the base for the rest of the spec.

 

The specs:

Car:

93 Jspec 6spd, 64k miles

 

Engine:

2JZ-GTE stock bottom end, head and cams

XS Power manifold

XS Power wastegate

XS Power downpipe & screamer pipe

XS Power intake pipe

Boostlogic T67dbb

Boostlogic oil feed/return kit

Aeroquip water feed/return kit

AEM filter

Greddy 3 row FMIC

Plus many XS Power, Aeroquip fittings and pipes...

 

Fuelling:

Stock rail, stock feed

800cc Power Enterprise injectors (flow tested)

Single walbro

Aeromotive FPR

-6 return line

 

Electronics:

Greddy Emanage Blue

Fields harness

Blitz SBC-ID III

Greddy boost guage

AEM afr gauge

 

 

More to follow...

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The base point for the conversion is the XS Power single kit bought from ebay (User id Xs-Power). The kit was £599 inc delivery and consisted of the following:

 

http://img466.imageshack.us/img466/5623/forum1zd1.th.jpg

http://img483.imageshack.us/img483/3441/forum2fw0.th.jpg

 

Next, the turbo, courtesy of Terry S. This included having the elbow welded on by BL (this will cause problems later...)

http://img352.imageshack.us/img352/8350/forum3jw9.th.jpg

 

BL Oil kit again from Terry S

http://img356.imageshack.us/img356/3502/forum4vh7.th.jpg

 

And a whole load of other bits I've been collecting the past few weeks.

http://img375.imageshack.us/img375/5349/forum5cq8.th.jpg

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Firstly well done on doing the spanner stuff yourself..........

 

........whats the procedure like for getting something like this thats fully installed up and running?

 

is it 'simply' a case of getting a mapper to come to you to put on a base map and tweek it from there?

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........whats the procedure like for getting something like this thats fully installed up and running?

 

is it 'simply' a case of getting a mapper to come to you to put on a base map and tweek it from there?

 

Its pretty much the same for all if you have an open ECU. I'll cover it in more detail later, but basically once everything is installed you load a base map to the ECU, this is a rough map which is matched some basic criteria such as injector size and cams. This allows the car to be started and run off boost. Its enough to get you to the mappers or even just driving around (slowly!). Once you get to the mappers the fun can begin with a full map.

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After a few weeks of hunting around I figured screw it I'll install it myself :Pling: ...

 

I found a real satisfaction of doing it myself and if you've got the stockers off which took me a good couple of hours! Then the fitting is relatively easy :) What’s the total cost of the project at the moment? I know i went well over budget but hey never mind :eyebrows:

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Its pretty much the same for all if you have an open ECU. I'll cover it in more detail later, but basically once everything is installed you load a base map to the ECU, this is a rough map which is matched some basic criteria such as injector size and cams. This allows the car to be started and run off boost. Its enough to get you to the mappers or even just driving around (slowly!). Once you get to the mappers the fun can begin with a full map.

 

thought as much.........its seems to me that this mapping lark is the last barrier to the complete DIY'er.....i know Ian C kind of learnt from scratch so i wonder if with the right bits and bobs (wideband, det cans, laptop.....?) its possible to learn this side of things too and therefore become totally selfsufficient........

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I found a real satisfaction of doing it myself and if you've got the stockers off which took me a good couple of hours! Then the fitting is relatively easy :) What’s the total cost of the project at the moment? I know i went well over budget but hey never mind :eyebrows:

 

Got to agree, though its caused skinned knuckles & untold amounts of bad language, its very satisfying to strip and build it on your own :)

 

I don’t know the total cost yet but my budget was blown about 1 week ago! I expect total cost to come in under £2500. I wasted at least £100 on buying wrong fittings, parts that weren't required etc. However I should make around £600 back from selling off parts from the XS power kit and old TT stuff.

 

Final cost should be around £1900 once its fully mapped.

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Got to agree, though its caused skinned knuckles & untold amounts of bad language, its very satisfying to strip and build it on your own :)

 

I don’t know the total cost yet but my budget was blown about 1 week ago! I expect total cost to come in under £2500. I wasted at least £100 on buying wrong fittings, parts that weren't required etc. However I should make around £600 back from selling off parts from the XS power kit and old TT stuff.

 

Final cost should be around £1900 once its fully mapped.

 

Thats a good set up for very little money matey i spent more like double that and then some :( I know what you mean on the old swearing front! those last couple of manifold bolts underneath grrr!

 

Due date is this Saturday (11th Nov) :sos: It doesn't look too likely right now!

 

Good luck matey hope you get it done! It really is well worth it :)

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I won't be covering the strip down in detail as thats already been done in great detail by TLicense, here: http://www.mkivsupra.net/vbb/showthread.php?t=82952

 

Thanks Tony for the great write up, it was a huge help :)

 

Instead, just a few quick shots of the progress and some comments. Last look at the TT system:

http://img390.imageshack.us/img390/4785/forum6ar0.th.jpg

 

Next drain oil and coolant, then remove the airbox and IC pipework:

http://img295.imageshack.us/img295/6478/forum7dt2.th.jpg

 

Now its just a case of unbolting the pipework, coolant and breather lines, then the turbo heat shield. I thought I was doing well at this stage after about 2 hours work (little did I know what was to come!):

http://img393.imageshack.us/img393/9153/forum8xh3.th.jpg

 

Now its time to remove the turbos. They are secured by 3 nuts at the top and 3 from underneath. The 3 on top came loose after a lot of WD40, a 20inch breaker bar and 17stone of idiot hanging onto it. Not to bad so far...

 

Next came the 3 nuts from underneath, they were on VERY tight and I could not move them using the 9inch spanner that fits into the gap. You cannot use a socket as there's no space. It took 6 hours (no joke) of messing around with different spanners extensions and more WD40, propane gas and eventually 2.5 foot of extension sockets to get those nuts off. Managed to bend 3x 9inch 1/2" drive bars in the process too!

 

All that to get to this stage:

http://img465.imageshack.us/img465/5140/forum9dz5.th.jpg

 

The manifold comes off next and after the last part it was a piece of cake, it came off in a couple of minutes:

http://img369.imageshack.us/img369/9803/forum10xi3.th.jpg

 

Next up, the build :D

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Looking good.

 

I've never taken the turbos off the manifold. I always removed the whole lot in one piece. The bottom manifold nuts are a pain to get at but it can be done with a wobbly socket. Mind you, I've not done it with the engine in situ. Having the engine out of the car helps a lot!

 

I'd also like to say how good it is that Darryl has used thumbnails linked to full sized pics. It's such a pain when you're trying to read a thread and the page keeps jumping about as full sized embedded pictures that you've already seen are slowly loading.

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nice one homer will be following this thread all it's way, i too also done all the kit etc myself and can whole heartedly be with you on the bleeding knuckles and swearing front :D :taped: i used greddy and boost logic parts all through and have spent about 7k ish and still have to pay for autronic ecu 1.2k and mapping circa 2k all in with ecu.............................should have gone xs power way :( hope we both get some good results :cool:

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