Question for you guys with homebuilt turbo systems.

[Chaotic_Warlord]

Ok I am starting to get prepped for the spring when I will be attempting to boost my car and I have a couple questions for those of you who created your own systems (IOW didnt purchase a full turbo system from somwhere) I am going to do this on a budget since I am not looking to do much more than 8-10psi to start off with so I'm going to use a small turbo from the junkyard. I am wondering what all will I need in the line of hoses and lines and where can I get them from, preferably for not to much money. I know I will need to get an exhaust manifold and the exhaust parts to go with it as well as the proper fuel parts. I also know I will need to get oil lines but other than that I don't know what else to get. I'm going to try to get a turbo that has an internal wastegate and I also plan to get a BOV. So where did you DIY guys get your parts from? Also would a SMIC work (ie one off an old MK3 Supra or 1G Eclipse) or should I just suck it up and get a FMIC. I can find the hoses to feed from the turbo to the intercooler practically anywhere so that won't be a problem. So here is a review of what I want to know:

1)What lines and hoses do I need?

2)Where can I find said lines and hoses?

3)Would a SMIC work or should I just suck it up and get a FMIC? What size should I get?

Finally is there anywhere out there that has a digram of how all the vacuum lines, oil feed lines and coolants connect from the engine to the turbo or do I need to find a guy with a KA-T in my area to help me with the install?

Ok I think that's all I need to know for now thank's for any help you guys can give. Like I said I'm doing this on a budget and I really don't need to drop 2K for a complete system when I'm not planning to run more than 10PSI and that much will be pushing it. Again thanks guys I appreciate any help you give.

[brunswick240]

Heres what i suggest, find a t25, medium size fmic, relocate the battery or just get a smaller one (youll be glad you got the fmic in the long run), you need coolant lines for the turbo, oil lines, turbo manifold, dump pipe, downpipe, vacuum lines for the bov and waste gate and boost gauge, youll need a boost gauge, bov, oil, bung for the oil pan, oil filter, T for the vac lines, premium gas , clutch, airfuel gauge, some sort of fuel air management (im going with safc2), I suggest actually getting your turbo, lines, mani, and the important stuff like that new, you dont wanna have to worry about the turbo having a bizzilion miles on it and blowing on you the first week you get it done...but hey if you wanna talk to someone about putting a homemade kit together shoot me an email at [email protected], or im me at brunswick240 and ill chat with you...nico helped me a ton, now i gotta repay the community . But ill try to help you im currently doing my own homemade kit right now, so i know a good bit and am getting some great experience. So lemme know, hope this helps.

[crzycav86]

I hate to sound like a d!ck, but just do more research.

I was in your position a little over a year ago. I wanted to go kat, but needed to know the specifics. Just read all of the threads in this forum religiously. When people mention things like fpr vacuum lines or oil pressure sensors or pcv breathers, just search and you'll find out what they do.. and hopefully find an answer from there.

The key for searching is to be very broad. In your search, use keywords that people would have written in their posts.

good luck man

[pr240sx]

What lines and hoses do I need?

You will need oil lines, both pressure and drain. If the turbo have coolant lines, you will need to tap into your cooling system. Check the KA-T FAQ for more details on oil lines,options and bungs needed.

2)Where can I find said lines and hoses?

Everywhere, from the internet, several oil line kits on Ebay or several stores, even at your local autoparts!

3)Would a SMIC work or should I just suck it up and get a FMIC? What size should I get?

If you want to go cheap and easy on your install, I highly sugest using a SR sidemount intercooler and lines. Using this, you will cover 3 things1. intercooler2.air lines3. BOV with recirculation

You will need also more fuel (via bigger injectors,370 or bigger) something to control bigger injectors (like a SAFC) and timing (a MSD BTM) or both at the same time (not cheap) a reprogrammed ECU.Bigger fuel pump (Walbro)You can use a JGS manifold cheap and reliable or buy one used.A turbo from a Z31(best) or a SR turbo (cheaper but smaller on hp goals) or do it right and get a T3/T4 turbo just in case. you can seva a ton by using a internal wastegated turbo.Downpipe but this is most of the time custom made.Exhaust (2.5 or bigger)misc. things like colder plugs, silicone tubing, etc.Good clutch!!Boost gaugeFirst of all, check the condition of your current engine, compression, leakdown, etc. Then decide your route.As for boost controller and turbo timers; these are optional and only add to the total cost of the proyect.I spent like 2 years in searching the parts and researching the forums (Nico and other ones too)reading and understanding understanding the KA engine.What started with a Volvo turbo, ended using a T3/T4 turbo with water intercooler, reprogrammed ECU fine tuned with a SAFC and a BTM just in case of a overboost situation, Centerforce Dual Friction clutch and plate, custom made 2.75 exhaust, Walbro pump, 370 Sr injectors (looking for bigger ones, maybe no larger than 550)Have been boosting from this past September with no problems. Daily driver, hard driven in mid 80 to high 90 temps @ 8 psiMy sugestion:RESEARCH, read and learn from the others. No KA-T is the same as another. There are several routes to reach your goals.Also, keep in mind this statement

CHEAP-FAST-RELIABLEyou can only choose 2

[Chezedik]

Again, you should research, particularly the sticky that says read this first. There is all of the info you need in there (what oil lines, how to read a turbo map, etc). That will help.

[thekawaii]

I hate to sound like a d!ck, but just do more research.

It's kinda hard to search at NICO. We're just loosing so many good info. We really need a good sticky system or something.

[Craving4Boost]

ka-t.org has a great sticky on what you need

[Iamjohnhayes]

are you a single or dual cam ka?

[Chaotic_Warlord]

Ok thanks for the response's even if they basically just told me to search. Eh I expected as much. I checked out the sticky over at KA-T.org and it was incredibly helpful. The only thing I still can't figure out is how everything goes into place. I'm not a total idiot and I do know how turbo systems are setup but all the ones I've ever seen came with a turbo from the factory. It'd be really helpful if I could actually see where everythign went. I could really use a diagram that shows how everything is connected, especially the vacuum hoses. So here's basically what I know, I know the exhaust manifold goes in place of the header and the turbo on top of that, the oil return line feeds into new bung placed in the oil pan and the feed line is teed off from the oil pump. The air intake hose then feed into the inlet fan and a downpipe feeds into the exhaust. On the intercooler side one hose feeds into the intercooler from the turbo and the one feeds from the intercooler into the intake manifold? The vacuum is fed off of the brake master cylinder vacuum line right and one tube goes to the wastegate, one tube goes to the boost gauge and the others feed into what? Does that sound about right? if so it sounds fairly simple to install. Now as far as the fuel goes what would happen if I use to large of an injector? would i just ruun super rich (ie say I ran 550cc when I really only needed 370cc). I know I'm going to need to run a larger fuel pump, but I don't know the first thing about fuel injectors size or fuel maps or even impedence factors. Like why is 5 volts too much for the MAF to handle. I really do want to learn and I am trying, been reading up a lot about this stuff, but I'm still not understanding how to fine tune the system so it runs right.

[Iamjohnhayes]

ok as for vacum lines you can uses t connectors or a vaccum block so that the vacum can come from one source. for saftey's sake i like to set up the wastegate vaccum of the compressor housing. it is a little higher of a reading that what your engine sees dude to the pressure drop from the intercooler, but i would rather be safe and run slightly lower boost (by no more than 1 psi) as for larger injectors it depends on what your using to run the injectors i believe you can reduce the duty cycle with the safc but im not sure. im running emanage ultimate witha wideband which lets me keep the air fuel ratio from running rich b/c i have 460cc injectors and my turbo is getting shipped to me in a few days.