P057's BT thread

[helmetface]

TMIC's are uglier than I remember...

[p057]

been so tired i forgot to post up completed results.


Well, the bay doesn't look much different. I did leave the downpipe and manifold heat shields off and the turbo is a bit beefier and easily noticeable now, but not sure if picture worthy. May go outside in a bit to snap a quick one just for proof of completed task

currently getting tuned, just been crazy scared to drive it, especially after another local MS6 ( @RhoadBlock) had a bad BT experience and resulted in quite a bit of damage.

I can't afford that, so i'm taking it a little slow.

First impressions are holy cow turbo lag. You really have to appreciate how well the K04 blends decent power with daily driveability(that even a word?). For the first 3000 RPMS, i'm basically getting crap for power, feels like a N/A 90's crapbox Kia. 3100 hits and even though i have boost turned about as low as it can go, it feels like it has tons of potential.

Recommendations for what i would change if i did this again:

1. Bolt-on kit was good. Silicone from turbo to intercooler NEEDS STRETCHING. DO NOT try to put that thing on the turbo first, put it on the intercooler as it's I.D. is the same as the intercooler, meaning it just barely fits without a stretch. Either pull on it or put it in some hot water for a few minutes and then pull it around the intercooler.

2. Coolant return line does not reach at all, you HAVE to get a new 17/32 hose (if you want it to connect to the coolant return properly. I just got new 15/32 hose and joined it to the OEM 17/32 tapered to 15/32 hose. I think those are the right sizes. If anyone asks, i'll go get the boxes and confirm it.

3. I wouldnt stick with the stock turbo's inlets and intakes... I can tell some of my lag is attributed to this stuff. going from just a hair above 2" to 4" is just insane. I currently purchased the CPe big turbo inlet hose from a member on the forum, and am going to (reluctantly) purchase a new CPe XcelXL once i hear back from Edgeautosport. They're getting a lot of my money this month... hahaha.

4. ABSOLUTELY make sure to check that you have the right height on the oil and coolant return line and make sure your clamps are facing the right side of the car..... i lucked out on the coolant return.... the main clamp coming from the metal banjo fitting to the rubber hose was facing the wrong way AND loose. It leaked coolant at engine operating temp. luckily i did not tighten it enough to prevent me from turning it around to tighten it. it would have been a painful mistake having to take nearly half the crap off around it again. the oil return was done perfectly. I was really worried about it failing on me since I cut it quite a bit, but i'm glad i spent so much attention to it.

5. Instead of clamping some of the hoses when pulling off the k04, i would have opted to cap the feed/return coolant nipples, as you barely have enough room to do the install (on an MS6) as it is.

6. I would have also gotten a friend to help. Doing all of this by yourself is a PAIN. it really sucks and actually physically hurts due to all the bruises and cuts you'll endure trying to pull on things and juggle parts around. Get a buddy to help! it would have made this 25+ hour install go MUCH quicker.

7. buy a gallon of coolant from Mazda before you start. it costs 20 bucks per gallon jug, you only need less than half of it to refill what you lost in your coolant reservoir tank.

8. Get better allergy medication, or do your install ANY other time of the year. Also, use bug spray liberally.



anyone else with questions/commentary, let me know. I'll be happy to answer.

Install was pretty straightforward and didn't really need a how-to to complete it. Honestly, the downpipe is on the same level of difficulty as this thing was. That or i just learned my car's anatomy a lot better since then..

[bmylez]

After you've done a turbo swap 5 times, you have way fewer cuts and bruises , but good job gettin her done on your own. Good feeling of accomplishment.

I have my car completely taken apart, waiting for new turbo tomorrow, and I think I have one small scrape on my left arm, haha.

[p057]

Originally Posted by bmylez After you've done a turbo swap 5 times, you have way fewer cuts and bruises , but good job gettin her done on your own. Good feeling of accomplishment. I have my car completely taken apart, waiting for new turbo tomorrow, and I think I have one small scrape on my left arm, haha.

I bet! yeah, if i had to swap it or replace it or anything, it looks like I can do it very easily in under a day now...

Was very nervous about kinking hard lines. Reality is, they are pretty darn stout and can handle a bit of abuse.

[jracer]

you should have texted me.. i would have come over to hang out help if i could
glad you got it all back together!

[p057]

OK, so I wasn't really done yet. Still getting tuned right now, but i've thrown a nice big pipe in the works.... literally.

big turbo deserved big inlet.




PG inlet pipe and cobb intake are too small.. i mean, 4" to 2.5" reducer? damn.

Got a CPE big-mouth inlet pipe from a user on the boards and "built" my own intake out of parts.
Note that I really had to bend and finagle the stupid PG turbo inlet pipe to get it in there to connect up to the turbo intake side... There are a lot of electrical things in the way and some tubing and heater hoses... Getting something even BIGGER in there will be interesting to say the least. at least I'll be "done" after this.

here's the parts list:
Custom 3.5" inlet pipe.

(order from Treadstone)
* Treadstone DENSO 3.5" MAF (65)
* honeycomb air straightener for MAF (15)
* Treadstone Medium, 3.5" Neck to accept 3.5" MAF pipe. (28)
Shipping: 14.65
tax: 8.58 (i live in FL)

(order from silicone intake systems)
* 3.5" to 3.0" 45* bend silicone reducer, black (20)
* 3.0" stainless steel joiner (7.99)
* (1) 3.5" T-bolt clamps (2.60) (note: i ordered two, but the filter comes with one so the second was unnecessary. Go ahead and order it if you want to be on the safe side though.)
* (2) 3.0" T-bolt clamps (5.20)
SHIPPING: 8.99
Tax: 0

I had a metal connecting pipe leftover from some other parts i ordered, so i didnt actually purchase. you'll need that to connect the inlet to the CPE pipe.
I also picked up a crankcase breather filter from Pep boys for roughly 10 dollars. It looks just about exactly the same as the one that comes with the cpe XcelXL. Only problem is that crappy breather has too small an I.D. I just bored it out with a pen blade and patience. Got it up to about 1/2 inch I.D. to JUST snugly fit on the crankcase breather port.
I feel my parts list above replicates the CPE setup pretty well, minus the $100+ extra charge and .25" smaller MAF.


Note that this is a BIG friggen MAF pipe. I am not even sure the car is going to like this in the long run. Drove it around and home tonight (about 20 mile drive) and it ran great... kept out of boost mostly.. hit maybe 10PSI at the highest.
If it ends up not liking it, i'll let you guys know and i'll downsize it to 3" or 3.25".

Also, i am not a fan of the honeycomb filter, I guess the good part about it is that it will reduce some flow, probably preventing it from getting out of hand. It will also probably do a better job than the other straighteners i've seen. (So far it's doing a fantastic job though.) Really shitty part is that it looks like they just cut it out of some material they have a big bulk amount of, it doesn't look perfect and to get it in, you need to press it in and crunch in some of the outside material. It sits pretty snug, but i feel like i should put something in there to prevent any possible movement.

[p057]

update: car loves the 3.5" MAF. everything flowing nicely.
Finally got boost dialed in and am sending logs to tune.

wheee.