1zz Turbo build take2!

[thetyrant]

Ok i stupidly sold my SP240 turbo kit while i worked out what i was doing with my poorly engine, thats all sorted now so going to build up another turbo setup for it, this time its a low budget initial build just to get me going and then as things progress will look to uprate and change a few things down the line once i make a plan for rest of car.

Ive decided to started with a Malian Log type manifold despite my reservations on these as i expressed on anther thread, but to get me going its the easiest option so manifold ordered end of last week from Lewis Winpenny/ Roadster Sport Ltd and it arrived today see below...

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Externally the quality is pretty decent and looks nice and solid, flanges are not perfectly flat but not far off and i can dress them up at work, problem started when i inspected it internally and seems ive been sent a "not quite finished" one   the runners on cyl 2 & 3 have not been ported out properly where they join the log tube and there is a step blocking flow,, i spoke to Lewis and he offered to exchange it no question, however i dont know if they are all like this or not so im just going to finish it up myself which wont take much.

Pic below showing the before...

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Pic below after i dressed it back with powerfile, still a little bit to do but its nearly there and a lot better.

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Also when i got home had to mock it up on spare engine im on rebuilding, sits ok and think i can make it work so once i get this engine finished and next track event out the way will get started on fitting it to my car.

Pic of it mocked up..

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[105e]

Can see your reservations about the manifold,  while it looks well made the flow must be terrible.

[thetyrant]

Can see your reservations about the manifold,  while it looks well made the flow must be terrible.

Its certainly not the smoothest flow path but it will do the job i think and relys on brute force to get the gasses into turbo, will be interesting to see how it compares to my previous SP240 setup (same turbo just different manifold) which i have a lot of data from/

This manifold design could be easily improved with some small changes, tapered collector being main thing to help with flow, also angle its mounted onto main log body puts the turbo a long way back from engine, probably to allow bigger turbos but anyone wanting a big turbo setup would want a much better manifold anyhows!, the other manifold i was looking at (turbokits.com cast one) puts the turbo too close to engine block to mount it the way i have it above which is my preffered setup and why i didnt go that way, with turbokits setup if you mount this way it fouls on engine block, anyhows at least i have something to work with and looking forward to after my next track outing on 20th September when i can get on with building it on car.

Pic showing clearance between turbo and block, plenty of room for GT42! ..lag city

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[McSmallface]

Any update on this? I've been looking through turbo conversion options and the Roadster Sport Ltd manifold was one of the main ones I was looking at but your pics/description has put me off.

[1979scotte]

Any update on this? I've been looking through turbo conversion options and the Roadster Sport Ltd manifold was one of the main ones I was looking at but your pics/description has put me off.

Anything cast will do the job.
There are a couple on ebay.

[McSmallface]

The only ones I can find on eBay in the UK are the Roadster Sport Ltd ones.

[thetyrant]

Anything cast will do the job.
There are a couple on ebay.

Any links to them? only seen silly money ones last time I looked.

[thetyrant]

The only ones I can find on eBay in the UK are the Roadster Sport Ltd ones.

I ended up selling it all due to changing plans! Now looking to start again and roadster sport ones only sensible money option I've seen, they are not best design but will do the job and I will probably end up with another one.

[McSmallface]

The only ones I can find on eBay in the UK are the Roadster Sport Ltd ones.

I ended up selling it all due to changing plans! Now looking to start again and roadster sport ones only sensible money option I've seen, they are not best design but will do the job and I will probably end up with another one.

The only other one I can find is a cast one that's nearly a grand! I only want to run a low boost conversion (180-200bhp tops) so I'm guessing that manifold will do despite its flaws?

[1979scotte]

The only ones I can find on eBay in the UK are the Roadster Sport Ltd ones.

I ended up selling it all due to changing plans! Now looking to start again and roadster sport ones only sensible money option I've seen, they are not best design but will do the job and I will probably end up with another one.

The only other one I can find is a cast one that's nearly a grand! I only want to run a low boost conversion (180-200bhp tops) so I'm guessing that manifold will do despite its flaws?

Watch the skid factory on YouTube you don't need a fancy turbo manifold to make good power but you do want it to be strong and last.

I can't seem to find the ones I've seen previously. 😕

[McSmallface]

I can weld so I could make one but I don't really know the science behind the type of design I would need so probably easier just buying one.

[1979scotte]

I can weld so I could make one but I don't really know the science behind the type of design I would need so probably easier just buying one.

Make a log manifold out of steam pipe. It doesn't have to be equal length or purged or anything like that.

[thetyrant]

I can weld so I could make one but I don't really know the science behind the type of design I would need so probably easier just buying one.

I'm tempted to make a simple log type like 1979scotte says, basics of the megalin/roadster sport one with some small tweaks to improve design and turbo position,however for what they cost probably just buy one as more than good enough for your power goals which are similar to mine and what I had with last turbo setup.

[McSmallface]

What turbo did you have on your last build? I was attracted to the roadster sport one due to T25 fitting as due to only wanting a relatively small bhp increase I'd be shooting for a smaller unit for quicke spool and more physical space in the engine bay.

[1979scotte]

What turbo did you have on your last build? I was attracted to the roadster sport one due to T25 fitting as due to only wanting a relatively small bhp increase I'd be shooting for a smaller unit for quicke spool and more physical space in the engine bay.

The offical TTE turbo came with a TB2559 that was good for around 190 and Silverstone performance manged to get 230 out of them.

If I was doing a turbo again I'd go with a GT2554R. Or Chinese equivalent.

[McSmallface]

That does look perfect for what I want although it is quite a price jump from a T25. I've only experience of thrust bearing turbos from back in my ford escort days so curious to know the advantages of ball bearing, is it just a quicker spool with BB?

[thetyrant]

What turbo did you have on your last build? I was attracted to the roadster sport one due to T25 fitting as due to only wanting a relatively small bhp increase I'd be shooting for a smaller unit for quicke spool and more physical space in the engine bay.

My first kit (which was basically the SP240 with extras) used a garrett turbo from a Saab 9000 but there are a few versions, this is a like for like one that i bought to replace it when i suspected oil seal issue - Ebay Saab Garrett turbo  i got it without needing to do exchange but see then need a core unit now or pay £60 surcharge but still a cheap turbo,  it spooled quick and made approx 230hp easily at around 8psi on my car according to datalogs/virtual dyno etc.

I will probably use same again and its what i have in pics on this thread which is the spare from original kit i bought, i sold it with megalin manifold but its not being used so i can get it back, its a cheap and solid little turbo which spools well and flows plenty of air for my power goals, maybe some gains from a more modern design but i doubt there is much to be gained to be fair at this level and newer designs are much more cost.

Cooling the intake is the key depending on car usage, if its just road use a rear mounted air to air IC like the SP kits uses isnt terrible and if boost is kept low it can just about cope, if planning to track car or run higher boost then a decent chargecooler setup is the key and what i will do next time, my last kit had the SP240 Air2air and it was ok on road but on track only took a couple of laps to send temps up above 50c and that wasnt even a hot day and boost only 7psi, it was right on edge of accceptable for me and think a hot day and more boost would of pushed it too far for saftey without having to dial back tune to cope.

[McSmallface]

I don't intend to do any track days and I only want below 200bhp as I've got motorbikes for track days etc so I just want a nice manageable slightly quicker car. Saying that I would probably go charge cooler anyway just to increase reliability as the engine is over 100k so want to try and get as many miles out of it as I can before I have to rebuild it.

[thetyrant]

I don't intend to do any track days and I only want below 200bhp as I've got motorbikes for track days etc so I just want a nice manageable slightly quicker car. Saying that I would probably go charge cooler anyway just to increase reliability as the engine is over 100k so want to try and get as many miles out of it as I can before I have to rebuild it.

Sounds good a little saab turbo would do the job then, only potential issue i found was the actuator i got with the rebuilt unit in post above was 9-10psi whereas the one on the Sp240 kit was 6psi, i felt 6psi was a nice safe spot and good for keeping intake temps down and still made around 200hp at that, i would rather have a lower pressure actuator and use boost controller to increase if required as like to be able to turn boost down if required. Anyhows just factor in getting a lower psi actuator if you went for the turbo i linked above.

Around 200hp and similar torque in these cars makes them a rapid little motor also the extra slug of torque low down means you can be lazy with engine and no need to revs its nuts of to make rapid progress

All this turbo talk has got me motivated to get back on with mine, ive got a trackday booked for early may so will get that out the way first then get going on turbo again, ive still got the Emanage blue fitted from 2nd attempt so i just need to turbo hardware sorted and i can get it up and running, will probably switch to a Link or ECUmasters further down line but the EMB should be ok for low boost starting point

[1979scotte]

I don't intend to do any track days and I only want below 200bhp as I've got motorbikes for track days etc so I just want a nice manageable slightly quicker car. Saying that I would probably go charge cooler anyway just to increase reliability as the engine is over 100k so want to try and get as many miles out of it as I can before I have to rebuild it.

100% go charge cooler the tte and sp intercooler are pony.

[McSmallface]

I did contact roadster sport as they mentioned a full turbo kit available on their manifold listing.

He replied saying a full kit with everything you need for £2200-£4200 depending on options (which includes ecumaster emu black) or a basic kit for £995 which includes everything you need except turbo, ecu, injectors, charge cooler or meth injection and wideband sensor.

[1979scotte]

I did contact roadster sport as they mentioned a full turbo kit available on their manifold listing.

He replied saying a full kit with everything you need for £2200-£4200 depending on options (which includes ecumaster emu black) or a basic kit for £995 which includes everything you need except turbo, ecu, injectors, charge cooler or meth injection and wideband sensor.

Everything you need lol.
That's just turbo manifold and lines I would imagine for 995.

[McSmallface]

So the kit consists of:
Manifold
Downpipe
Turbo to v band adapter
Charge pipe
Tial style blow off valve
Goodridge braided turbo feed hose
Oil feed adapter fitting
Oil return hose
Various AN fittings for the feed and return hoses
Sump AN adapter
Braided water feed and drain hoses
Water hose adapters
Water hose banjo fittings
Silicone hoses for the charge pipe
Silicone hoses for the vacuum feeds
Exhaust gaskets
Studs and nuts for the manifold, turbo and adapters
Various clamps for the charge pipe fittings
Air filter for the turbo

[JB21]

Defo need to try a 1zz turbo at some point, bet they're chalk and cheese compared to my 2zz.

[1979scotte]

Defo need to try a 1zz turbo at some point, bet they're chalk and cheese compared to my 2zz.

They're very different .

Tbh I find the 2zz totally underwhelming. Especially if the exhaust has been cocked up.


Mike's 2zz with cams and ecumaster is pretty good and they go nicely when rotrexed.

I'm a torque fan so they just don't suit me.
Turbo is the best bang for your bucks imho.