My twin scroll BW s300sx 88-75 BT build

[djuosnteisn]

My original BT setup was a 0.82 a/r t3 3071... and was plagued with a cracked manifold. When i finally pulled it off to start working on my new setup, I even found an unfinished weld on the manifold.... which was incredibly frustrating. That meant i had exh leaks since day 1 with that setup... and with a manifold that cost $1k plus 6 mos of waiting... was just unacceptable.

So i set out to do it again, and hopefully right this time.

I picked up a Borg Warner 88-75 from a local buddy for cheap:
Full-Race Motorsports

He gave me 2 different hot sides with it, one of which was a 1.0 a/r (t4 flanged) twin scroll. So i figured with only 2.3 liters of displacement, and a monster journal bearing turbo to spin, i'll need all the spool help i can get... thus a twin scroll manifold was in order.

I figured, since i'm building it, and absolutely loathe working on a turbo in the stock location.... might as well go top mount.






This was the first manifold i've ever built, so i hope it works out well. I used schedule 10 stainless cast elbows & piping, which has nearly double the wall thickness of my previous $1k manifold. Many people use sched 40... but i'm hoping sched 10 will cut it, especially with an additional brace between the flanges.


In order for the hood to close... i had to cut and angle the compressor outlet some. It's a 3" O.D. compressor outlet lol. Here it is gonzo-fied.




The turbo is a monster. Capable of 75 lbs/min.






I then fabbed up a 3" down pipe to mate the monster turbo.






I wanted to keep the car somewhat mild mannered off-boost, so i threw in a resonator pipe i had just laying around. Should help keep the volume down quite a bit.



Also threw together an intake to feed the beast. This one is 3.25" I.D. but eventually i'll probably max the maf, and need to go to a 4" pipe. I already have the couplers and pipe to do this, just need to get a few other things squared away.




For oil feed and return, i modded the oem lines by cutting them off part way, and welding on AN fittings.






The oil return line was awfully close to the wastegates, and wouldn't easily route up under the CHRA without touching exh runners... and thats a def no-no. So i had to fab up a oil slide to bring the AN fitting out from under the turbo.






Once that was done, it was time to start bolting shit up and get the dump tubes fabbed.

First i threw on the manifold & twin gates.




And routed the dumps down and out by the axle. This is a pic of the first part of the dumps. I still need to get a better shot of how the look complete, cause it's awesome. I'll update the post with the better pic when i have it.



Here's a pic of the finished piping tacked together.




Once the dumps were done, it was time to throw on the turbo and oil lines.





You can see how the return line is far enough away from the WG's and turbo, which is good. I plan on putting some heat shielding around the return just to be safe.

There was some bend in the return line, but no kink, so i think it should work fine.

The feed line comes out from under the alternator... all the way under the manifold, up and around by the intake. It wasn't hooked up in this pic, but you can see the routing fairly well.


Then throw on the down pipe and hook up the o2 sensors.



You can see the oil feed line better in this pic.


Then throw on the hot pipe section from the turbo outlet.




Install the intake and MAF sensor.








And voila.... one absolutely ridiculous looking turbo setup lol. The pictures don't really do it justice IMO, cause this things look insane in person.





I started it up Sunday evening... but still need some more hose clamps, a boost 'T' for the WG's and coolant. It was making a clacking noise from under the valve cover, but i'm hoping it's just a lifter, and the noise will go away lol. Tonight i'm gonna start it again and let it warm up, and maybe even take it for a very light cruise. After a heat cycle, I'll also re-torque all the exhaust hardware.

I hope to god the clack goes away.... hahaha.


Next up on the list is HKS ignition amp, tap my cold pipe for wmi and a few other nick nacks. I have a triple gauge pod with an oil pressure gauge (courtesy of Matt Damond, big thanks) that needs to go on as well.


And once all the hardware is vetted... it's time to tune and see what this setup can do.... oh and yea.... stock block.... so this will certainly be a good test for it's capabilities.

[BrianZX10R]

fucking A dustin

your Hot side on that turbo is so big that your Exhaust looks like a macaroni Noodle

[Click Here]

This looks fucking unbelievable!!!!!

Fantastic job man. I cannot wait to see what thing can do when you start tuning.

[turd burglar]

skeet skeet skeet skeet skeet! clickin might be your vvt even, but either way, good luck man, looks foooookin amazing!

[Docnox]

Craziness. I can't even handle how fucking awesome that looks. Can't wait to hear that puppy spool up!

[Dano]

as always, excellent work Dustin!

lovin your oil return fix....

[Chriscote]

your the man btw

[m4tic]

dustin are you fucking serious?

i hope your mind is the only thing thats blown

[jack_hammer]

very nice!

[socks]

ibtw





in before the win!

[IshiKage]

fucking tits. that set up is b-e-a-utiful. awesome work

[PunjabiPlaya]

hot shit. need vids ASAP, even if they're like this guy:

skip to 1:08 for the show

YouTube - 1200hp Supra Dyno

YouTube - 1200hp Supra Dyno

[MS33SM]

That thing is huge! How tight is the clearance against your hood?

also:

[Speed13]

That turbo is insane!!! everything looks insane, but so so wonderful

[-cj-]

Nice setup man! I'm jealous. I'm definitely leaning towards a top mount setup now....

Did you do all this in your home garage? What kind of fabrication tools do you have access to??

[djuosnteisn]

Originally Posted by MS33SM That thing is huge! How tight is the clearance against your hood? also:

Not horrible actually. I'm gonna pull the liner off and put my turbo sock on the hot side. Things clear great though IMO.

Originally Posted by -cj- Nice setup man! I'm jealous. I'm definitely leaning towards a top mount setup now.... Did you do all this in your home garage? What kind of fabrication tools do you have access to??

Yup, did it all in the garage. I have a band saw, belt sander, grinders / cut off wheels, and a TIG welder. My TIG is a Hobart EZ Tig (same exact thing as the Miller Diversion 165).

You'd be surprised how much you can do with some basic tools and a lot of patience lol.

[AZSPEED3]

Awesome man, that is beautiful.
That thing is a monster, keep the cats away so they don't get sucked in.

[djuosnteisn]

Originally Posted by AZSPEED3 Awesome man, that is beautiful. That thing is a monster, keep the cats away so they don't get sucked in.

I think your supposed to actually feed it a cat every thousand miles or so just to keep it happy... That's exactly why i've been stocking up on the kitt3hs

[AZSPEED3]

Originally Posted by djuosnteisn I think your supposed to actually feed it a cat every thousand miles or so just to keep it happy... That's exactly why i've been stocking up on the kitt3hs

I got one that I could send your way, lol.

[the_caruch]

god dammit dustin. you make me feel like an automotive-dumbass when you post up shit like this.

that setup is ridiculous! MUST HAVE VIDEOS

i applaud you on your continued custom work to the platform

[JacksonMS30]

Originally Posted by -cj- Nice setup man! I'm jealous. I'm definitely leaning towards a top mount setup now.... Did you do all this in your home garage? What kind of fabrication tools do you have access to??

^^ Dustins fabrication tool...



Very nicely done sir! What kind of power are you thinking it will make?

[qtrmile beast]

If you are going to blow the stocker you are not going to pussy out like the rest of us with just a little rod through the back of the block you are going to COMPLETELY destroy that fucker!!!!!!

Cant wait to see this against that mustang you raced in the last vid or maybe you can catch up with that supra this time and have a rematch!!!! GOOD LUCK DJ i'm pulling for you!!!!

[mtnrunner]

Looks sick man! must be nice to be sooooo close to being done after this long. Cant wait to see vids of this thing ripping and spinning all four!

[triplejumper18]

You're gonna feed Kat to the turbo gods?

[rodrigo]

looks great mr. hawkins , awesome that you took so many pictures as well. Cant wait to see this at a SEA LEVEL drag strip.

keep kicking ass ese

[djuosnteisn]

Originally Posted by lenny127 looks great mr. hawkins , awesome that you took so many pictures as well. Cant wait to see this at a SEA LEVEL drag strip. keep kicking ass ese

I'm hoping this turbo is big enough to bring sea level to me.

[rodrigo]

lol, well put.

[superskaterxes]

as i said the other night, lolz @ last march when you said your built motor setup would only take a month hahahaha

hopefully it was all worth it!!! make us proud!!!

[JacksonMS30]

I think Dustin is trying to be the first to put an MZR rod into outerspace...

[Alpha]

NASTY! I can't wait to have my fab guy tackle a nice top mount EFR setup!

[R.MS3]

Tits... that reminds me i need to get my rebuild going... fuck.

[Speed3eak]

DJ, between you and jwilks I guess we're going to find out how much power these rods can take before they give out with a good tune.

cue applause

[dooderek]

god i hate you

[X-Man]

Stock block... man... i cant even imagine the size of your nuts

But if there´s anyone that can pull it of it´s you

[Dash08]

I think half the forum wants to stick their dick in your turbo because that shit is fucking sexy.

Nice job on all the fab work man.

Seeing this makes me want to learn to weld. I'm tired of buying other peoples shit. I'd rather make my own.

[dooderek]

i bet even in your car ill still run 15's

[09Speed3Z]

So, uhhhhhh yeahhhhh, East Coast Meet in Myrtle in May.


You bringie?!?!?!?!?!! SHOTGUN!!!! Hahahahahaha

[Darksun280]

DJ you haven't learned from my fail? You're maf is going to hate life on that bend plus it really should be about 11 inches away from the turbo and 5-6 inchs away from any bend. MY 240 couldn't catch idle for shit off Decel being as close as yours is to the turbo and on a bend to boot. Pre pare you're self for tunning issues.

[cld12pk2go]

Originally Posted by Darksun280 You're maf is going to hate life on that bend plus it really should be about 11 inches away from the turbo and 5-6 inchs away from any bend.

Exactly what I was going to mention.

Everything else looks like pure win though...

[silvapain]

Originally Posted by Darksun280 DJ you haven't learned from my fail? You're maf is going to hate life on that bend plus it really should be about 11 inches away from the turbo and 5-6 inchs away from any bend. MY 240 couldn't catch idle for shit off Decel being as close as yours is to the turbo and on a bend to boot. Pre pare you're self for tunning issues.

Agreed. The MAF needs laminar flow to accurately read mass airflow, and the closer you put the MAF to the turbo or a bend, the less laminar the flow will be. The rule of thumb I've been taught is 2 times the MAF diameter from any bend (upstream or downstream), and as far from the turbo (or throttle plate in N/A applications) as possible.

In addition, you may have to rotate the MAF around while tuning to get the best (i.e. most linear) response in relation to engine/turbo RPM's.

Don't get me wrong, I'm not hating; I just want the car to run as well as possible.