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My 89 GTi project (Turbo)

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instant_shine

Post subject: Re: My 89 GTi project (NA)

Posted: Tue Dec 09, 2014 11:18 am

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

Allright, time for an update:

Here are a few things I've been busy with the turbo project. I'm doing this all by myself.
I've noticed the small little things takes a lot of time to get done.

Things still to do:
-Custom inlet / outlet holes onto intercooler (to make piping work easier)
-Intercooler bracket install
-Oil feed line and drain line install
-Wiring up of turbo timer, dual stage boost controller (se7en circuit)
-Socket install ECU

etc.

_________________
1991-GTi: JE 75mm 11:1 pistons,Ported head, Single UD pulley (OCC),Sandros chip,Aluminium flywheel,3tech 222/365 cams, Cultus headers,Cultus IM,50mm tb,Crane cams adjustable cam gears,Apex suspension, 4.39fd GB.
1989-GTi: 3Tech 210/340 Cams,Cultus IM, B&G springs, TD04L turbo, Apexi SAFC, Suzukird UD pulley, Circuitse7en dual boost controller, AEM wideband, AEM water / meth injection kit, HKS bov.
2001-Altezza AS200: Stock.-sold
2003-EVO7 GT-A
Aruba "one happy island".

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t3 ragtop

Post subject: Re: My 89 GTi project (Turbo)

Posted: Tue Dec 09, 2014 4:54 pm

Suzuki Elder

Joined: Mon Dec 01, 2003 12:47 pm
Posts: 11675
Location: columbus, ohio

the project is looking good, man! :wink:

_________________
1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd.

My Turbo3 Project
My Cardomain Page -Ol' Blue
My YouTube Channel
My Photo Gallery
SAAB Sonett II

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Wed Dec 10, 2014 8:05 am

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

Thank you.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Mon Dec 22, 2014 7:45 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

I'm routing the vacuum hoses but I can't source small enough clamps. Can I just use tie reps on the vacuum hoses?

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t3 ragtop

Post subject: Re: My 89 GTi project (Turbo)

Posted: Mon Dec 22, 2014 8:56 pm

Suzuki Elder

Joined: Mon Dec 01, 2003 12:47 pm
Posts: 11675
Location: columbus, ohio

i have used zip ties on some small lines. i have popped a few, too.

when zip ties don't hold i replace them with clamps.

on my blue monster turbo3 project i did everything in special aba clamps from 3mm up to 26mm.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Tue Dec 23, 2014 1:46 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

t3 ragtop wrote:

Awesome. Thanks again!

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Sun Dec 28, 2014 5:24 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

ok so here goes another update.

After turning the catridge and compressor housing I had to fab up a bracket for the actuator. It's being held by 2 bolts at the water in/out of the turbo. I'm not going to use the water cooling.

Also connected some hoses for the oil catch can. The oil catch can is going to be inside the car. Not much space in the engine bay. I'm still thinking if I should reroute the breather filter of the catch can to the outside. Don't want the gases in the cabin.

For the oil feed line I used 4An fitting hoses, 1" extension 1/8" bsp male/female, A T-fitting for the turbo feed and relocation of oil pressure switch sensor (15psi) for warning light and oil pressure sending unit for the gauge.

For the Oil return I used a "no welds" 45 degrees fitting (10An) and also an adapter with 5/8" barb for the drain hose. 5/8" is the diameter of the return of the TD04L-13T.

The test fitment of intercooler piping. Most intercooler piping inside diameter are 2".

I still have to close one side of intercooler and open up a 2" 90 degree so I can connect the compressor housing to it.
Everything is still test fitted. When I'm done and everything is in it's place I'll tighten them up securely and use the zip ties for the vacuum hoses.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Wed Jan 07, 2015 12:21 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

Got the car painted last weekend.

Sorry for the picture quality of the last two pictures. it was getting dark.

There are still some bodywork left like painting rubber / plastic seals etc.

FYI paint code is 8m6 from my altezza.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Wed Feb 11, 2015 7:40 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

I'm going to vent the crankscase directly to an oil catch can. Installed a 6an fitting with 90 degree.

Also sprayed painted my rims with white epoxy paint in a can that is used to paint fridges. :lol:

They actually turned out good IMO.

Also mounted the Apexi SAFC. I have yet to wire it up.

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Turboraz

Post subject: Re: My 89 GTi project (Turbo)

Posted: Sat Feb 28, 2015 11:17 am

Joined: Thu Feb 05, 2004 9:17 pm
Posts: 119
Location: Tampa Fl

Could you give me the specs on the JE pistons

Thanks

_________________
89 Suzuki Swift Turbo
03 Infiniti G35 sedan

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Sat Mar 21, 2015 12:10 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

Turboraz wrote:

Could you give me the specs on the JE pistons

Thanks

I'm not using JE pistons in my turbo engine. :huh:

The pistons in the turbo engine are stock.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Fri Jun 10, 2016 8:13 am

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

Quick update:
Removed the fuel tank. Installed a 5 gal. fuel cell.
Also installed an Aeromitve fpr. The knock off was giving me issues. Buy the real thing the first time.
Also have a marshall pressure gauge insalled. And an external walbro fuel pump.

THere is a chance I might go to the track tomorrow again.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Fri Jun 10, 2016 8:33 am

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

A pic of the last time I was at the track.

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instant_shine

Post subject: Re: My 89 GTi project (Turbo)

Posted: Sun Jun 12, 2016 8:42 pm

Joined: Thu Apr 15, 2004 12:27 am
Posts: 3054
Location: Aruba

Did a few runs on the 1/4 mile yesterday. My best run is a 14.10 @ 106.4mph. I was boosting 18psi on a stock engine.

More info and pics here: viewtopic.php?f=24&t=61742

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