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Turbo charging an I6

6K views 32 replies 19 participants last post by  Eldomo 
#1 ·
I will be the first to admit that I know next to nothing about setting up a turbocharged engine. I was wondering if the turbo boffs out there could explain what bits u need, what they do, how much they cost etc as I am sure alot of people would be interested to red it for theselves. U think we all pretty much know how a turbo works but how would u go about setting one up ( on a budget ) for an inline 6. Which turbo to use etc etc

I found this site which is good
http://www.turbofast.com.au/TFmatch.html
 
#2 ·
I'm trying to do just that If I get enough guys intersted. But it's a diy [do it yourself] job.Possibly along the lines of two kits one with original exhaust manifold no intercooler low boost a budget kit/ povity pack to get started. Another with custom manifold Hi Flow T3/4 "or" whatever.[conservative I know but very streetable]

After doing just that to a V8 I'm wanting to do same to the ED XR6 ..As each one is made it gets cheaper...
kiwi_reign@yahoo.com.au Check out The Market on f/f....
 
#3 ·
My medium-term shopping list includes a pair of T3 turbos with internal wastegate, exhaust manifold, piping, 3" exhaust, uprated injectors and fuel pump, ECU remap, BOV of some sort, and various internal engine mods.
 
G
#4 ·
If I had a spare $8G laying around I'd be going for a full BAXRT motor drop-in. It's a much more refined motor and with a aftermarket computer will give you 300kw, thats before you start modding it.

Oh yeah... and the glorious thing is, you'll still get better fuel economy then what you currently get out of your standard i6 motor right now. :bouncesmk

Just waiting for my lotto numbers to come up... and then I'll get right onto this conversion. :|
 
#5 ·
anyone got a heads up on where to buy a custom exhaust manifold for cheap?

Im planing on doing a 250 Xflow and as the engine comp of the unleaded XF motor is already 8.7, the comp doesnt need to be dropped that much to retain good driveability.

My plan for an engine is acl dished duralites pistons, moly rings, shot peened rods, LPG spec cam, ARP rod bolts, shot peened push rods, hardened valves, and thats basically where i get stuck. Im not sure what else to upgrade and what to use.

I will be using a gas research throttle body for the setup, as it has been proven to be a very easy way to make a lot of power, not to mencion its all EPA legal!

I was looking at either running a single s5 rx7 turbo, or twin s4 rx7 turbos. WIll just depend on where i can get a manifold from, and how much it will cost to get one made up!!
 
#7 ·
unknown user,

try doin this:

bore the block out,
shave the head,
hardened valves,
hardened valve springs,
port and polish the head,
grind and balance the crankshaft,

the possibilities are endless, there is no such thing as a fully worked engine as an engine can never be fully worked.
 
#8 ·
Im in the process of doin a turbo 250 efi, i was originally goin to build a stock motor, get a decomp plate and run an aftermarket ecu, but after bein in my mates xf turbo i decided to build a killer engine.
 
#10 ·
yeah, i know nik at turboworx very well, so ill probably get him to build my motor and do the manifold. If not, ill get jason to knock one up and he'll be taking care of the tuning for sure.

Just a long way to take a car of that size on a trailer when the tow car is only a ZL injected 6. Turboworx is just around the corner literaly.

Ive costed out a full rebuild on an EA 3.9L motor, with components that 68OOST used in his motor, and it doesnt seem like a lot of $$$ for a big hp motor!! ill be using lesser pistons thou, as i wont be running near as much boost or as big a turbo.

ive seen john's xf (back when it was red and the twin BOV as a wastegate) up close not long after it was built, and all the pipe work is flawless!! Jasons twin turbo XE is also an absolute work of art.
 
#11 ·
Yeh johns car is a work of art.....that big plenum chamber......that new exhaust manifold.......10.87 pass at calder........what more can u say

yeh jasons XE looks like it'll make some serious power
 
#12 ·
I want to turbocharge a XF fairmont ghia, but i want to put the turbo and intercooler and piping etc in now while my other engine is getting built.
The stock engine has a compression ratio of 8.8:1. Would it be possible to put a turbo on now and have the boost low and driveable and when the new engine goes in wind the boost up to about 14-18psi mark and up the power delivery significantly to at least 300kw at the wheels? How would i do this? Can i have big turbo on the stock engine putting out a safe amount or will i need a small turbo then a big one when the better engine is put in?

Thanks
Dan
 
#14 ·
Can i have big turbo on the stock engine putting out a safe amount or will i need a small turbo then a big one when the better engine is put in?
i wouldent put the big turbo on a stock engine, if anything de compress the stock motor by using a copper head gasket, and put the small one on, and just wait untill you put the better, stronger motor in untill you put the big turbo on it..
 
#15 ·
turbo set up

the falc engine needs little or no mods in turbo applications in 15psi set ups
what is important is good cooling and fueling

my own engine i have built up runs a complete acl race series kit and some new rod bolts.

the engine is running 32 psi

if ur on a budget i suggest this

*use a ef 4.0lt block,crank and rods
*run acl ea race series pistons 20 tho over (have ur block hones 3 tho to accept these)
*run a complete acl race series rebuild kit
*have ur 4.0lt standard rods shot peened only (do not linish)
*get the block o-ringed
*the cylinder head can be left standard (altho a reco is recomended)
*some new head bolts
*use a ed intake manifold if on a very tight budget if the budget permits run the ef lower intake manifold and make up some bell mouths and a 6-8 lt plenum.
*use the 444cc skyline injectors (not sue which ones- memory is failing me in my old age lol) or rx-7 550cc pink injectors
*a rising rate regulator is a good thing to get as well
*as for a turbo maifold i can knock on up for $600 if you need
*as for a cooler you can run a cut down truck core or use two series 4 rx7 intercoolers joind together (around $500)
*use a bosch feul pump (044 is a big suka which is rrp $550 but flows 1000hp worth of fuel but there are cheaper and less flowing option available)
that should see you holding 25 psi very easily for a long time to come
*as for turbo sizing a pair of t-28's is a good option or if your not too worried about moving the earth at low rpm then a t04 s trim is the best you could buy for the falcon in general driving 2300-6000rpm. or a t66 for 3000-6200 rom range

if youve got the cash try a gt 42-45 roller turb!

hope that helps, anything else just ask.

cheers.joe.
 
#18 ·
i have a eb2 fairmont ghia and am also thinking about BOOST, i am only after some thing to run at 5-10 psi for daily and then 12-15 psi for a bit more fun. what sort of money we talking?rough estimate.

what is available second hand? eg. turbo, cooler.
Is it a good idea to go second hand on ths sort of stuff?
for a low power turbo conversion is it possible to use a smaller turbo than what has been recomended? eg. T28

cheers!
 
#19 ·
one more question! sorry

my car is an auto and i really can't be bothered with a manual.i no they go faster but hay, call me lazy.

whats the power limit on the eb auto boxes?

thanks heaps! all help means that i keep the ford and don't get an import. i like my car and would love to see it kill a couple of imports!
 
#20 ·
Well I have done a bit of research with a turbo install. The cost is dependant on how much rwkw. In stock form the engine can take at max 8psi and then needs to be rebuilt for more psi.

For a kit you could look at something like TSA kits whcih go from around $5000 for stage one 5psi or $6695 for stage two 7psi i think. These kits use T3 turbos. You also have the option of getting a turbo specialist to do a custom kit which could include a rebuild or not, the sky is the limit. Most people I have spoken to recommend is a T4 for a mild setup, for use in daily drivers. Which add upto around $10,000 fully installed.

Second hand stuff is okay, but make sure that it is still good nick or else you are looking a rebuilds for the turbos which adds unneeded costs.
 
#21 ·
turbo manifold $800
t04e turbocharger $1000-1500
42mm external wastegate $450
intercooler piping $400
PWR VL-t front mount cooler $900
blow off valve $300
high flowed injectors, 600cc $360
adj. fuel regulator $220
bosch 040 internal fuel pump $750 installed (good for 600hp)
EFi Hardware's Hawk ECU $1100
2mm decompression plate $????

i probably missed a heap here but i'm sure someone will let me know.

i'd advise against the 044 fuel pump as it is external and will cost more than the 040 in th end. the t04e is the most suitable turbo for the 4ltr donk, you'd easily get 230rwkws with 15psi.
another reason i'd advise the to4e as it's easily upgradable for future mods. i've seen an AU run 20psi and manage 250rwkws, with a very similar set-up.
 
#24 ·
I reckon you'd chew out a T5 first, but it would be a pretty even race.....

9psi's auto has lasted a fair while im lead to believe, he'd be the one to talk to.

I wouldnt trust either box personally, which is why i havent really bothered getting my turbo bits together. Joes formula using EF block has lots of merit.....

If it were mine, i'd got a old Top Loader with renegate sequential shifter, or a 1500 dollar Supra Turbo conversion from someone like dellow. And if i was REALLY being keen, couldnt go past a old C4 three speed auto.

There is also the AOD american 4 speed auto, have fun getting it behind the six, and i suppose if you were that way inclined you could get a turbo 350/700 etc from the Holden/GM camp....hell go a powerglide!

Just another note on the T5, Eddy Tassone ran his 10XX (cant remember the EXACT number) twin turbo V8 Commodore on the Dyno at summernats with a T5 box. The winning run was done in fourth gear, which apparenly is pretty close to being a 1:1 ratio, reducing stresses (and that much hp isnt enough stress!!!) in the box. The box lasted the full run WITHOUT grenading, however, a teardown revealed most of the thing was pretty well bent/twisted.
 
#25 ·
yeah as for gearbox....
i myself am running a supra turbo 5spd box in my ea turbo set up the box's are about 1000-1500 to buy and a conversion kit goes for about 700 bucks
tho i will be selling my supra box andconversion kit next year (wont handle the power or tourqe of my stage 2 development next year) and in place will go in either a tremec bos as used in the ts50 t3 or a t56 hsv gts box (mmmmm...6 speed...mmmmm) (again tremec box) ,and my car is looking like it will be doing a low 10 sec pass at the moment

if you are on a extreme budget a stoko engine rebuild (stock pistons and all) and a pair of ct26/28 (toyota supra 3.0lt single turbo) turbo's and a set of the skyline injectors i mentioned earlier a feul pump of higher cappacity and a decent clutch on a t5 will do the trick and should see you on 250-300rwhp very very easily..

i am about to build another car up for a mate (genuine brocky ea turbo) its designed to be a budget beater...
we will be seeing if we can build up a 400 rwhp ea turbo for under 4 grand...
plan consist of a new t04e core and exhaust with 1.00 ar exhaust housing then a to4 s trim comp cover and comp wheel (.85 ar- tho not comfirmed)

i will be making the manifolds and cooler and doing all the install.

a set od modified vn commo v6 injectors and bosch swimmer 040 pump. all on a stock motor.
car has the t5 we will only be putting in a flat shifter mechanisim and a good brass button clutch, a set of up-rated uni's and a 3.45 limo diff from an xr. and hope to see this car drop into the 12's

also just about to start on a 3rd project for another member in the fastfords.org car club...
this one is a ea 3.2lt cfi beast 5 spd
we will be putting in a t3/cast exhaust manifold/svo intercooler (its all out of the ea brocky turbo mentioned above) and a mpfi we will only be looking for 240-260fwkw from this set up. for around a 2500 spend and hope to see this one run a low 14 sec pass
 
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