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Date: 3-27-07 06:59
From: Pinepig in Citrus Heights, CA 
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )  
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It's back there somewhere but I'll just type it again.
I made the spacers out of 2 pieces of 3/4 MDF cut about 1/4" bigger than the beauty ring, just stack them together after you put a bead of glue between them. I used some med thickness CA ( I always have a bottle in the fridge for cut fingers ). The hole in the car was done with a cut off wheel on a die grinder and has about 1/2" of space around the magnet.
The material I used to cover them was purchased from a car stereo install shop, they use it to cover sub boxes. You can get it in black and a kind of pepper Grey fairly easy. It isn't the toughest stuff in the world but it is real easy to work with. I purchased 2 yards ( 6 feet wide ) to do my box, back cover and the little speaker pods.
To cover the speaker pods just cut a strip about 2 1/2 inches wide and long enough to wrap completely around it. Staple one end down, wrap it around, trim to length and staple the other end down. Use some staples to help hold it around both edges until you get it screwed into the car and the speaker screwed into that, then the staples holding it around the edge really don't matter. Put the staples in the back when you screw it down and they don't matter either.
I put the tweeters just under the dash as high as I could get them on the sills and the sound stage is pretty good and the tweeters aren't that noticeable tucked in tight to the dash.
I highly recommend the 6 1/2 inch speaker for the mid bass and a separate tweet for the proper sound stage. The sub is up to you, my car still sounds pretty good with the sub off but even at 40 yrs old I still like my music LOUD ( and clear ). There is just something about Pink Floyd and Rush while you are carving the twisties at the proper sound level. :-) _________________ Charlie Mac in Sacramento.
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Date: 5-12-07 04:31
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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It's been a long time since I've updated, sorry about that, seems like every time I got something done there was a relevant post somewhere else in the FAQ so it went there instead. Since the last update I've started working on the turbo stuff ( didn't I promise that a long time ago ). These included the very nice Ireland Engineering aluminum radiator ( outstanding price for what you get ) and a 2 1/2 inch exhaust from the down pipe back prepping for the turbo.
I have the turbo in hand and all rebuilt, a Holset HX30. Manifold is almost done thanks to Massive Lee's beautiful SS flange, it's a basic log made out of 304 weld els. I have yet to put the standoff for the turbo and turbo flange on it yet as I need to take the exhaust off my car to do it, it must fit PERFECT.
Today I spent some time actually getting the intercooler in the car. The core is a 12.5x6 by 3.5 vertical flow, bar and plate. I got the core and endtanks from Treadstone ( nice folks to deal with ) , they make one the right size but the tanks are welded on the wrong way so I welded them on myself so the inlet and outlet are on opposite sides.
After figuring out where it was going to go there was no way that 320 fan was going to work so a low profile fan was sourced off Ebay that was only 2" thick and that was installed. I've also rid myself of that manual fan controller and used a 85c fan controller off a 318 in the water neck off the head, I know some of you say not to put it there but my megasquirt says I never get above 192 deg ( under 3 o clock on my cluster ) before the fan turns on, simple wiring with a relay and switch to complete the ground
The hood brace in the nose on the drivers side was in the way of a charge pipe so it had to be trimmed down, I'll end up re-welding a new brace in back to the radiator bulkhead at a later date because I don't like the way the hood flops around when open with it trimmed down.
The hood had to be trimmed to make room for the top piping so I took it off and did it with a cutoff wheel, I also don't like the way it flops around now so I'll be welding an inverted brace in there and repainting the hood when I do the bay.
If you were to do it like this I'd get a 3" thick core instead as the lower center driver side grill screw tab had to be trimmed off to make room for the intercooler outlet, 1/2 less and it would have been a non issue.
I'm trying like hell to have the turbo in and running by Palo Alto but I don't think I'm gonna make it. If not I'll have the only intercooled normally aspirated car there and look like a real dork ( who's kidding who, I'll look like a dork anyway )
A couple of pics
 _________________ Charlie Mac in Sacramento.
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Date: 5-27-07 10:27
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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OK the next step is done, turbo in and running ( well I might add after a bad day yesterday, more later )
Turbo is a Holset HX30 from what I understand was used in a diesel forklift, LOL. Not much is really known about it as the Honda and E30 crowd seem to like the HX35 off a 5.9l Dodge pickup much better, the reading I did seemed to lead me that and HX35 would be a bit large for a M10 for low end power ( street driving ) The HX30 is the next one down from Holset and I found a compressor map on Hondatech for it one day that seemed to show it would stay in the 75% window up to 2 bar and 350cfs of air, works for me. Basically it means that up to 30psi you can make 350hp ( real rough head calc ) I really like this turbo in the deuce ( I'll explain more later.
I'd really like to thank Lee ( Massive Brakes ) for making me the header flange, beautiful work. The rest ( for the manifold ) was 304 weld els (sced40 ) and a chunk of 2x3 inch tubing that I had to split and taper to make the T-3 2x2.5 opening. A T3 flange was sourced off Ebay and Barry A gave me a junk head to use as a platform to weld it all up on. It took about 8 hours to cut it all to size and weld it up.
I sourced a few other parts on Ebay as well, a generic oil feed and return kit for T3 based turbos. The only problem is a Holset has a M12x1.5 oil inlet and NOBODY makes a oil feed line as far as I can tell so an adapter from the local parts store for 5$ to turn it into a 1/8npt took car of that. BTW the M12x1.5 is also the same as the oil pressure port on top of the head so get two and buy your oil pressure sender in 1/8npt and the plumbing for the feed line becomes very simple just add a T in between and run the line to the turbo.
The return line is just a couple of BIG barbed fittings and some high temp hose, I drilled a hole into the timing chain cover to get the return above the oil level in the pan ( it's kinda important to have the drain free at all times.
Right now I have the wastegate set to hold completely closed ( i had it wired open all the time for the trip to PA ) and be fully open by 10#s, there is a lot more power to be had by this turbo but it already ate a headgasket on my completely stock 8.3 to 1 motor ( told ya I had a bad day ) a Cometic head gasket that I had for the new motor sourced for Ireland Engineering that I already had meant I didn't have to wait for parts and had it running again in one day.
Boost starts creeping in about 2500rpm and by 3000 I'm seeing 6#, 10# comes on pretty damn quick after that, I'll run some logs tomorrow and give you guys some exact #s. I'm guessing about 200hp at this point ( kinda makes sense knowing what the factory turbos make at 7-1 and 7# of boost non intercooled ). I'm right at the limit of my 24# injectors at this point so until I drop the 42#ers in this is it. It's fricking quick even only using 1/4 throttle driving it around and letting it get to 4K rpm, shifting at 2500 makes you look a little saner to the sheep.
I'll get around to the new motor here when I get back from my 2 week vacation in Bonaire ( I have fish to look at and warm water to swim in )
I'm thinking 8-1 with forged pistons and SS valves with a 270ish cam and 22psi on race gas ought to get me to 300hp pretty easy, Lets break some parts. WOOT
Some pics ( damn leaky transmission ).
 _________________ Charlie Mac in Sacramento.
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Date: 5-28-07 03:43
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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I know you don't want it too close to the turbo for heat reasons and that was a pretty easy spot to put it. You have to recalibrate the LC1s every 6 months or so and it has to be done in free air, it's real easy to do where I have it now. _________________ Charlie Mac in Sacramento.
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Date: 5-29-07 10:20
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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I logged the car on the way to work this morning, guess I turned the boost up a bit when I was playing with the waste gate. Here's what I'm seeing.
6psi at 2500
7psi at 3000
9psi at 4000
11psi at 5000
14psi at 5600, and then I shifted.
AF are 11.5 across the board under boost ( did the pull in 3rd ), I'd like to lean it to 12 to 12.5 under boost, cruise ( off boost ) is 14-15 AFR.
It's running really nice right now. _________________ Charlie Mac in Sacramento.
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Date: 5-29-07 10:47
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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( Mr Burns ) Excellent ( Mr Burns ) _________________ Charlie Mac in Sacramento.
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Date: 5-31-07 07:57
From: TMK-001 in Geelong, Victoria, Australia
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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The question we all want to know is....
"Any scalps yet?"
:-P
Not that I encourage street racing or anything... _________________ 
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Date: 5-31-07 09:59
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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I ran into my buddy on the freeway today in his A4 Audi with a 1.8t. With just rolling on the throttle he was disappearing in the rear view so bad I had to go back and do it again in 4th to make him really feel slow. _________________ Charlie Mac in Sacramento.
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Date: 6-1-07 09:48
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder(update Oct 20th, stereo instal )
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With the air filter on the turbo whining and the BOV going PSSSSSHHHHT you aren't fooling anybody.
The Honda kids around here won't even make eye contact with me. _________________ Charlie Mac in Sacramento.
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Date: 7-3-07 10:36
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder (may 27th, turbo is running well ( again
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15x6.5 BBS RMs et33 with 195/50 15 tires
Coil overs up front on shortened struts with Rabbit inserts
Rears have cut stock springs and bilstiens. _________________ Charlie Mac in Sacramento.
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Date: 7-3-07 12:55
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder (may 27th, turbo is running well ( again
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The intercooler is a 12x3x6.5 vertical flow ( much more efficient than a horizontal flow ), the theory is that the greater the heat differential between the compressed air ( inside ) and the outside air the more heat exchanging occurs. On an horizontal flow most of the work is done by the first 8 inches or so of the intercooler so the last 12 inches ( if a 20 inch long core ) does relatively nothing. The size I used is about maximum if you go with a 3 inch thick core, a 16 inch wide one would probably fit if you dropped to a 2 inch thick core. Make sure whatever core you use will flow enough air for the HP you are looking to achieve, Bell intercoolers has a nice chart on their site that shows the figures for bar and plate cores.
The BOV can be placed anywhere in the charge piping ( before or after the intercooler ), I used the one from a DSM ( Eclipse ) because they are cheap ( 30 bucks on Ebay ) and work well as is up to 19psi, squish them a bit and they'll hold more boost without leaking.
Block is a stock 2002 motor ( 8.3 to 1 IIRC ) _________________ Charlie Mac in Sacramento.
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Date: 7-25-07 08:42
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder (new update June 10th ) (nt)
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The other day my buddy Greg gave me a manual boost controller so I put that in, note to self, check operation before installation. I had the MBC turned all the way closed instead of open to start with and the first run down the street was interesting to say the least. A quick look down showed the boost gauge pegged at 3200rpm ( 25psi) That can't be good on stock pistons. I've been playing with it all week ( touchy little bastards ) and finally have it set to 11psi, I still have the creep up top but it gets to 11 ( spinal tap reference ) quicker. I'm seeing positive pressure by 2000rpm. Turbo sounds wicked spooling up.
I put the 42# injectors in it today as the 24s were going static at about 5000rpm before the MBC, it was working fine anyway but I didn't like the fact that eventually they would burn up if I kept flirting with high RPMs. So I'm back to running data logs and getting a good tune on it again. I'll report back in a few days after I have it running perfect and let you know the difference a MBC can make ( plus a couple of pounds of boost ) _________________ Charlie Mac in Sacramento.
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Date: 8-24-07 08:35
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder (new update June 10th ) (nt)
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I used the 2.5 inch Vband kit .
Yep it's a 2.6 inch, so the 2.5 doesn't fit perfectly. to fix it I made a gasket out of some 16ga sheet metal to widen the tapered parts a bit ( a big thin metal donut ) , the 2.5 v band seals up just fine now. _________________ Charlie Mac in Sacramento.
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Date: 9-19-07 06:37
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder (new update June 10th ) (nt)
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thwack for a buddy having a problem finding the thread. _________________ Charlie Mac in Sacramento.
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Date: 9-19-07 06:40
From: cj in the BMW Sauber F1 car 
Subject: Re: My 500$ wonder (new update June 10th ) (nt)
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Removing that air injection pump will result in 10hp. Also you'll find your 1/4 mile times will drop 3 tenths.
:-D
Cris _________________ The rides!
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www.cardomain.com/ride/792793
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Date: 9-22-07 07:08
From: Pinepig in Citrus Heights, CA
Subject: Re: My 500$ wonder (new update June 10th ) (nt)
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| cj wrote: | Removing that air injection pump will result in 10hp. Also you'll find your 1/4 mile times will drop 3 tenths.
:-D
Cris |
Took that thing out when I did the water/methanol injection a few weeks back, 22psi FTMFW. _________________ Charlie Mac in Sacramento.
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