My Single Turbo Build
 

Well I have been working on this for a little while so I figured I would post some of the things I have done.

This is my second FD and ever since I have had it I have had secondary boost problems and smoking so rather than replace the twins and be stuck in the same problem I decided to go single. Granted the twins are amazing while they work as on my previous FD when they don't they sap away all the fun of the car.

For the turbine I decided after much thinking about my goals and the great help of Elliot at Turblown.net to go with his hybrid turbo.

http://i33.photobucket.com/albums/d5...7Single001.jpg
http://i33.photobucket.com/albums/d5...7Single002.jpg


For the manifold he also advised me to not get something on which the runner size was to big because I was not planning on running very high boost pressures as the car will see 90% street duty. I wanted something reliable and easy to fit and was lucky enough to find a used HKS manifold on the forums.

The flange on Elliots turbo is a different spin on the V-Band and it has for its purpose as I understand to eliminate lining up issues with the downpipe and provide and easy and reliable seal. However, if you try and put a regular Vband flange on there good luck.

This is what a regular Vband looked like after 30 minutes on the lathe at my friends machine shop:

http://i33.photobucket.com/albums/d5...7Single006.jpg

I don't know if the pictures show this to well but it really seats perfectly now.

http://i33.photobucket.com/albums/d5...7Single008.jpg

For the Fuel Rail I went with the KG setup. However, I don't like the fact that it doesn't have the fuel temp in it so we made a little adapter and I also covered it with heat radiant tape. I like this stuff alot, when I tested my rail if I apply 250 F to the rail the inner temp of the rail is 90F.

http://i33.photobucket.com/albums/d5...7Single003.jpg

Also, I haven't seen this anywhere but to get the rail to fit I had to grind down the head of the bolt quite alot or else the rail was resting and the bolt head and well this is something I just didn't like.

http://i33.photobucket.com/albums/d5...7Single004.jpg

The primary rails have been machine for 1/4NPT fitting.

http://i33.photobucket.com/albums/d5...7Single011.jpg

Finally fitting the filter is being a heck of a ***** but I chose the K&N RE-0860 which was the biggest filter I can fit in my space. I have heard many cars and I find that the best sounding are always those with the largest air filter and of course I wanted to most amount of air for my turbo.

http://i33.photobucket.com/albums/d5...7Single009.jpg

Also, for comparison I put it on top of my M2 Med.

http://i33.photobucket.com/albums/d5...7Single010.jpg

Nice build and thats a big filter!

I talked to elliot about that turbo also but i don't have my FD anymore.

Keep us updated

For the Fuel pressure regulator originally I had ordered incorrect fittings. I ordered standard 6an unions but I didn't like the idea of have a interior port with a flare. So I ordered the proper fittings for the regulator which are the black ones. Also the small plug is the one I originally ordered from Pegasus but when I got it I found the hex size way to small and didn't like the seal. I also found it kind of weird that Pegasus shipped me the plug and it had no O-ring so if I would have just installed it like that it would leak...

http://i33.photobucket.com/albums/d5...7Single005.jpg

Hmmm. I guess what I use as a standard DP flange is not the same as everyone else's. I'm sorry about the problem, I'm glad to hear you have solved the issue. You're build is looking good.

I would recommend welding those fittings in your primary rail, those npt fittings like to leak..
Good luck!

Thanks for your input Elliot.

For the primary it is just for mock up right now I will be using some high temp thread sealant(liquid) if I see any leaks during testing I will bring them in for welding.

By the way I am wondering should I have used thread sealant on the oil inlet of the turbo as the fitting seat fits into the turbo to form a seal?

I usually do, but its not completely necessary. Just be careful not to get any of the sealant in the turbo..