Big Single Upgrade
 

So far just the upgrade of the turbo, fuel system etc has taken me about 5 months, seems a long time but without spending every weekend and evening working on it, it seems to be coming along ok.

The car is a 1988 Savannah, running a bridgeport turbo, since the rebuild of the engine it's done about 2000km's, thinking that was a good run-in, I decided to upgrade the turbo.

The turbo I'm using is a MasterPower R596, my power goal is 400+ HP, only running 15psi, with luck this should be easily obtainable.

Masterpower R596
 

Here is a picture of the turbo, the hot side is a 1.0 AR, twin scroll. The twin scroll was so I could run the turblown dual waste gate setup.

The original hot side had a 4 bolt flange but I wanted to run a v-band, so I had one welded to the hot side.

v-band flange
 

here is a pic of the hot side after the v-band flange had been welded on.

When I had this done, I didn't weld the old holes up…a mistake…after getting it running, the exhaust must have blown through into one of the threads and caused an exhaust leak…this happened the night before the dyne run, so once again the dyne was cancelled!

Hi-temp coating
 

I had the hot side of the turbo coated with the hi-temp coating, this was done both inside and out, not sure if this will last but as an addition I will be using a blanket. I will be installing one of the PTP Lava blankets, this probably won;t help the hi-temp coating but will minimise under bonnet temp with luck.

Dual wastegate manifold
 

Because I didn't want to run too much boost, I decided to run a dual waste gate manifold and after looking at various options, I was pretty happy with the turblown manifold, took a while to get and as I'm right hand drive (RHD), but was very happy once it turned up.

I am running dual 40mm turbosmart wastegates, have also got dual EGT probes in the manifold and had Elliot coat the manifold in his hi-temp coating to again, reduce under bonnet temps.

Fitted!
 

Manifold is on, it's a close fit with both the wastegates fitted, will be even tighter with the plumbing attached and the downpipe in place!

Once the manifold was on, then it was time for a test fitting of the turbo...

A few other mod…throttle body...
 

Thought it best to keep the air flowing as smooth as possible and with keeping the inlet manifold to factory, I wanted to keep it as efficent as possible.

I basically removed the unused butterflies from the front of the throttle body and what ever else I could from the outside of the unit.

I removed the coolant tubes that run through t also and filled up any holes to reduce the chance of a manifold leak.

Most of the instructions for this I found on FC3Spro.

Koyo x-flow and taurus fan
 

I debated how to mount the taurus fan on the radiator for a couple of months while I did the bits and pieces, I wanted to keep the mounting as clean as possible so I was reluctant to use straps to mount it.

Instead, I welded some threaded lugs to the radiator and screwed the shroud to them, this way everything was tight and secure and reasonably clean.

Downpipe and exhaust
 

The down pipe I had to get fabricated, I had a couple of things that needed done with this, I wanted the waste gate runners as long as possible and the O2 sensor about 40" back from the turbo.

It worked out reasonably well, it's pretty tight in there, nothing touches the chassis or intake which was essential. If you're in a hurry to remove the turbo for what ever reason…exhaust leaks…it takes some time!!!!

I had two flex sections put in the wastegate runners, so with luck, any expansion will be taken up with these leaving the rest of the exhaust to move as it needs.

The exhaust system is a racing beat REV II from the bottom of the downpipe back, I changed the bolted flange to a v-band.

After removing the downpipe to fix the exhaust leak on the turbo, I thought it best to wrap it up, I used the titanium wrap, so with luck tis will handle the temp…we'll see...

For the fuel system, I am running 2 x 850cc and 2 x 1600cc controlled by a micro tech lt10s…not my 1st choice of ECU but it was what I had on hand. My next upgrade will be to go with an adaptronic or a Link, but this will be at a later stage.

For a fuel pump I'm running a Aeromotive stealth pump, I have a backup setup of dual walbro's. I am running stock lines up to the firewall, then I go into braided lines. I am running a Mahle porsche fuel filter, it is about 2' in diameter and is supposedly very high flow…but until I get it on a dyne, I can't confirm this.

After the filter, I have split the line feeding both rails in parallel returning them both to an aeromotive rising rate regulator.
At the moment I have the pressure set at 75 psi to get her running, initially it was set at 20psi and she still ran, once she is on the dyne I'll keep an eye on it to see how stable it is or maybe I'll have to upgrade to -8AN line.

Nice work on the downpipe. What size is it?

Downpipe sizing
 

The downpipe is 3.5" from the back of the turbo until just before the second v-band where it drips down to 3".

prior to going on the dyno.
 

The car has gone in to the tuners, been a bit of a delay with a couple of small issues but with luck she'll be ready to run by the weekend.

Clean setup. I like it. Hopefully there won't be too much lag with that big turbo.

what pulleys are they??

I hit 400hp in my S5 with a stock ports and a BNR stage 4 at 15psi so you should be fine

Not bad at all. also FMIC or stock top mount? I made also a setup like that for a friend and its running around 1.2 bar on the BNR stage4 but with stock top mount. I did not dyno it yet but if runs about 75% duty cycle on 550/1680 injectors with stock base fuel pressure and 11:1 afr.

tmic is for stock only...
That thing heatsoaks like a mofo, you need at least a fmic, those high intake temps are just detonation waiting to happen.

I was running a massive custom v-mount

Looks good man!

How's the noise on those gilmer pulleys? I've been thinking of picking up the same setup for my car but I don't want it to howl. I just hate how little contact the water pump pulley gets even with 2 stock belts on it. The last thing these hot rotaries need is a slipping water pump

-sean

gilmer drives suck

"yoohoo belt" ftw

will be interesting to see how the new generation master power turbos spool, my old T70 is definitely dragging ass compared to the most recent turbos of equivalent size.