Custom reworked turbos?

[CraigHJr]

Can you do a full upgrade turbo with a ported wastegate also? I seem to have a ton of overboost issues and think this is a neccessary step towards fixing it.

I may have also buggered my exhaust housing where the studs go. How does that affect the core for you guys?

[CaptainKRM]

we have not ported the wastegate on one of these yet. i would have to price out that option for you.

did you strip out the bolt holes?

[CraigHJr]

Yes the top center housing bolt hole is stripped, the block side upper hole may have lost a thread and need to be cleaned up. I didn't get to the lower ones yet but god knows I am sure they will not want to come appart either. If you can stick to a solid turn around schedule I can send my turbo so you can send me mine back, but if you could work up a price with a port job I would appreciate that.

[CaptainKRM]

we could try and rethread/retap that hole to a larger bolt size. it would be mismatched but it would work ok. i can stick to a three week turnaround right now.

[CraigHJr]

I will try to heli-coil the one stud with the turbo on the car. The plan now is to port the Cork DP as best as I can and put it back together. If I still overboost I will need to get the price for porting the turbo. I think I will send you mine in so no one gets screwed with it.

Now the reworked turbo will lose some spool speed but gains flow up to redline right? How much boost will it hold?

[CaptainKRM]

we've noticed in all but one or two of the reworks that lag is decreased and the spool is on par or faster actually. we've come to the conclusion that Truboost's is a dud, as i have gone back and tried to call/email those who have installed one for thier impressions of it and it has been almost universally the opposite, sadly. we're going to get truboost into a 2871 sooner or later and we'll inspect his turbo at that time. his was also one of the earlier units and we've made changes in the work since then.

we have mazdaspeed3s holding 20psi dynoing (with supporting mods of course) at 325 and 345 whp. one individual with a Cobb AP added the turbo, did no tuning (obviously, come on cobb!) and gained 30whp with the turbo alone being added.

[CraigHJr]

Alright Ken, First I had to pull my turbo off. My drills couldn't fit in there to squarely install a heli-coil on the car. Second; can you suggest how to pull the exhaust housing off the center section of the turbo? I may as well port the wastegate on this turbo to see if it is even going to help. Third; can you sell me the 5 hole turbo gasket, 3 turbo studs and 5 turbo bolts? And fourth; do you have the V2 PG Mani in stock? If so can we switch my Cobb spring/ Forge wga orders for that? Give me a call to discuss if you don't feel like posting/pm'ing back.

[CaptainKRM]

Originally Posted by CraigHJr Alright Ken, First I had to pull my turbo off. My drills couldn't fit in there to squarely install a heli-coil on the car. Second; can you suggest how to pull the exhaust housing off the center section of the turbo? I may as well port the wastegate on this turbo to see if it is even going to help. Third; can you sell me the 5 hole turbo gasket, 3 turbo studs and 5 turbo bolts? And fourth; do you have the V2 PG Mani in stock? If so can we switch my Cobb spring/ Forge wga orders for that? Give me a call to discuss if you don't feel like posting/pm'ing back.

i can credit the WGA order for that. i did get the confirmation that the Cobb springs had shipped over the weekend. i do have manifolds in stock. i can sell you all the assorted parts you requested, right around $50 for all those pieces. as for taking the center section apart, its not something i have personally attempted

[CraigHJr]

Edit: If you didn't change or send me anything yet (still send the Cobb springs) hang on till I get my thoughts in order reguarding turbos and that train wreck.

[CaptainKRM]

Originally Posted by CraigHJr Edit: If you didn't change or send me anything yet (still send the Cobb springs) hang on till I get my thoughts in order reguarding turbos and that train wreck.

cobb springs were sent. let me know on the other stuff what we can do - i have a core sitting here!

[subparpunk03]

Originally Posted by CaptainKRM we've noticed in all but one or two of the reworks that lag is decreased and the spool is on par or faster actually. we've come to the conclusion that Truboost's is a dud, as i have gone back and tried to call/email those who have installed one for thier impressions of it and it has been almost universally the opposite, sadly. we're going to get truboost into a 2871 sooner or later and we'll inspect his turbo at that time. his was also one of the earlier units and we've made changes in the work since then. we have mazdaspeed3s holding 20psi dynoing (with supporting mods of course) at 325 and 345 whp. one individual with a Cobb AP added the turbo, did no tuning (obviously, come on cobb!) and gained 30whp with the turbo alone being added.

Here's my dyno attachd... looks like I may have gotten a dud as well if my results are not consistent with what you've been seeing.

Any way to be sure mine is behaving as expected or not?

[CaptainKRM]

Originally Posted by subparpunk03 Here's my dyno attachd... looks like I may have gotten a dud as well if my results are not consistent with what you've been seeing. Any way to be sure mine is behaving as expected or not?

PM sent

edit - think i answered my own questions. i went and googled some other mustang dyno charts to better help me read this one. i have a few questions to ask before i think all this over; were the runs done back to back or same day, say right after the install? what other mods are done to the car? how does the car feel with the turbo? were there other modifications done with the turbo install at the same time? we have made small changes to what is done to the turbos since the initial few, but nothing that would drastically increase or decrease performance. our feedback with yours and one other early tester has been near-universally positive. the turbo alone will not hold 20psi of course, you would need boost control, so hopefully i didn't confuse anyone by making that comment above.

i have three new reworked turbos scheduled to come to me, so if we determine you have a unit which is doing what its supposed to, i'll send you another to try without fail, and if that works better, you can keep that one and i'll check the faulty one out at the machinest. some of the cores we got back and started with required serious work, so as we go down the road we may be more selective in whose we take back if we see that as a factor that is going to hamper a rework.

[subparpunk03]

So the runs were done 3 days apart. Very similar weather conditions.

You'll notice the torque and power curves are losing a little bit down low, and gaining a bit up top (due to running leaner)

What worries me is that the boost is significantly lower throughout the RPM range. This may indicate that the shop didn't get everything back on 100% tight and I have/had a boost leak. This didn't worry me at first, as it makes sense that the clipped wheel is causing less boost when running at the same WGDC as normal in open loop, however if this is not what other people are seeing then I'd obviously like to identify the problem.

Are there any other dynos of the reworked turbos?

So the mods are cobb intake, ap stage 1+, and the forge valve. The rpmc inlet was added later, and then removed. I didn't notice much of a difference with the rpmc inlet, maybe a slightly quicker spool.

As far as how the turbo feels... its definitely a bit laggier, but once it spools, it seems to consistently hold less boost than it did before but not much difference power wise, except on the top end. Feels way better up top, especially with the FT cobb maps.

Ken, here is what I would like to do... I will take yet another pass at checking for leaks and try and get everything cleaned up, install the latest maps, and then run it on the dyno again, stock tune then AP tune back to back. I know a lot of people will be happy to see that I have a cp-e downpipe sitting here too so I might go ahead and install that before putting it back on the dyno.

I'd like to get some more info about how these things are "supposed" to behave without boost control. I suspect this is the expected behavior when nothing but the turbo is changed, but if there is evidence to the contrary, then something is up here.

[CaptainKRM]

Originally Posted by subparpunk03 Ken, here is what I would like to do... I will take yet another pass at checking for leaks and try and get everything cleaned up, install the latest maps, and then run it on the dyno again, stock tune then AP tune back to back. I know a lot of people will be happy to see that I have a cp-e downpipe sitting here too so I might go ahead and install that before putting it back on the dyno.

no problem. let me know what you find. either way i'm happy only when you are.

[mdogg]

Originally Posted by subparpunk03 You'll notice the torque and power curves are losing a little bit down low, and gaining a bit up top (due to running leaner)

Assuming that everything else remained the same between the 2 dynos, this is the natural outcome of the rebuilt turbo. The clipped exhaust takes longer to spool in the lower RPMs but then since it is clipped, it spins more freely in the upper RPMs - it's really nothing to do with running leaner. Now, if you also changed your tune coincident with the new turbo install, that may change.

[subparpunk03]

mdogg, thats what I thought. Like I said, I wasn't worried about it UNTIL Ken told me that other users were seeing quicker spool.

[CaptainKRM]

i think once we can get more custom mapping on your AP and run more boost out of the turbo than 15psi, we will see exponentially better results from your turbo. i may allow people to deduct the clipping option from the turbo build rather than force people into buying that. it would sale people money and i concede the fact that its not an option for all people's needs/tastes.

[subparpunk03]

Yeah, if you look at the post where I first put up my impressions (post #100) http://www.mazdaspeedforum.org/forum/foru...e-turbo-3.html

That was pretty much my conclusion. I apologize b/c my interpretation of what Ken was saying was that with nothing other than the new turbo, people were seeing quicker spools and bigger gains.

I'll definately keep you updated on what happens with the tuning. Something is in the works.

[subparpunk03]

So here's an update with the turbo "issues" I've been having. I went over it and did a really thorough boost leak test. Found several leaks, and a kink in the vacuum line that goes to the BPV. I beleive that in the dyno above, this thing was HEMORRHAGING boost. Some of these leaks may have been caused by my engine falling out and just pulling some things loose.

I just ordered a dashhawk, Ken, get that to me ASAP cause i'd really like to get some good accurate data logs to support what I think I'm feeling.

I seem to be holding around 15-16 lbs of boost on the 1.02 ap maps, which i think is still a little low (as expected) but its not 14 lbs low like it was before.

I'm going to schedule some dyno time to settle some things that have been bothering me.

1st run: Baseline (stock tune + my current mods)
2nd run: Baseline (AP 1.02 + my current mods)
3rd run: AP 1.02 + Downpipe

[CaptainKRM]

what kind of boost leak test did you do? this is positive news to hear. how much better has the car performed since you addressed these leaks?

[subparpunk03]

I checked all of the clamps from the turbo to the TB, two of them were loose-ish. I think this was my main problem.

I also checked all of the vacuum line connections I could find. These all looked fine, except for the line that goes to the bpv was sort of doubled over on itself and being pushed down on from the intercooler. So its likely that there wasn't much pressure going to the bpv so it was relying solely on the spring to keep boost from leaking.

Yes its performing better, but I still don't notice much of a difference over how it ran stockily (is that a word? it is now.) or with just an intake.

I will know more once I put it on the rollers and do some data logs.

[udontknowjack]

whats the latest on this? new dyno number?

[CaptainKRM]

we posted a dyno submitted to us in the listing for the turbo