Lude Generation

Right Guys,

I'm having some work done on my car this week so I thought I would pull over my turbo build-thread from over from PUK.

So here are the interesting parts:

Just a little of background on me and my cars. Before the prelude I had a nissan primera GT with a normally aspirated SR20 engine. I drove it around for a while did some pritty standard mods like exhaust and air filter and after a while fancied doing something a bit different. So i turbo charged it! and it was awesome. I did it on a really tight budget but as a proof of concept it works great. Unfortunally 2-3 months after being a turbo I crashed it all that effort wasted!

So after that I brought the prelude (back in march 2008) I did pipe dream about tuboing the car but as it was an auto (which was on its last legs) so it was never practical and a new that it would cost a lot more. To cut a long story short my prelude is now a manual and I have money to 'spare' and I started looking into it seriously a few months ago. I've been pulling all the parts that I think I'm likely to need. It all started gaining some serious momnetum when a brought the majority of a treadstone turbo kit from neilude (cheers mate ).

So part list so far:
Turbonetics T3/T4 turbo
Tubonectics wastegate 38mm (9 psi and 7psi springs)
Threadstone cast manifold ( I did want tubular but I could'nt find a sensibly priced one that would retain power steering and air-con
Vecco Intercooler and some pipework
Dump Valve
Oil lines + Tee piece
sump oil return kit
DSM 450cc injectors (peak and hold)
resistor pack to run peak and hold on post 1996 car
Down pipe for prelude/integrea turbo (this will need a fair bit of modding to fit)
Exhaust flanges and 2.5" stainless pipe to customise exhaust
38mm external wastegate pipe and 38mm stainless extension with custom bends
Walbro 255 fuel pump
Apexi Air filter and small breather pipe filter

And a power steering hose to replace mine as its got a hole in it!



The astute of you may have noticed that I have not included any engine management in the above list. this is becasue I am already running a Greddy Emanage, that was fitted to the car a while ago and I was running a really nice normally asperated map. but the stunning thing about this is all I need to do it fit the turbo and plug in the laptop then away I go! (in very simplistic terms)


Right I don't think I have missed anything out but anyway..I'm now packing off my car with all this stuff and taking the car over to Fusion Motorsport in Surrey. I know the guys down there really well and they have offered to help me out with the build when it comes to technical expertes and a full workshop! I have also taken the week off work and I'm going to try and get as much of this done as possible.

ight a few pics from yesterday and this morning:

I compleatly underestimated how much stuff I had pulled together it nearly didnt fit in the Lude!




As it arrived before I got started.


Tubo manifold and turbo fitted.


Its a bit blured but this shows the intercooler position.




So a bit of a summary of todays progress as can be seen by the Pictures the old manifold is off and the turbo one is fitted up with the turbo mounted in place. The oil feed has been tapped off the oil pressure sensor and relcoated the oil switch to further up the oil feed. Unfortunaly I had some issues with the brass fittings for one of the oil lines cracking so I will have to source a replacement for that tomorrow.

The sump is off and I've worked out how and where I want my oil return to go. The no-need to weld return pipe I have just wont fit anywhere on the sump as the inside edges have bracing and there is nowhere flatenough that will seal with a gasget. So I think tomorrow I am going to try and find a differnet type of fitting.

I also replaced my power steering hose as that failed complealy on the way down to the workshop and I left a trail of fluid all over the floor. The hose that needed replacing was the one that goes from the pump down the back of the engine and over to the steering rack. I didnt think this would be such a big deal to fit but all I can say is it was a real pain and that was with ramps good tools and half the engine bay and exhaust taken out already for the turbo.

A update on the progress, I have managed to source a new oil-line peice and fit that to finish the oil feed. I also managed to buy a really nice fitting for the oil return into the sump that should solve the issues with locating the return into the ally sump. I started fitting the oil return yesterday but didnt have a drill big enough at the workshop to make the hole so I need to finish that off today

I looked at the turbo exhaust down pipe that I brought from the states, it is supposed to fit a prelude, well it doent in the slightest. The turbo flange is not the correct orrientaiton, the cat flange is complealy wrong and only has 2 holes (my cat as 3) the length is not good as its too short. Also the whole thing is 3" and there is not a hope in hells chance that 3" pipe will fit between the engine and the front engine support bar. So after looking at this all I have decided to go custom I have been down to a local exhaust fab place and they have bent me the bends I need I now plan to weld it all up into a 2.5" custom downpipe.

Yesterday I also fitted the DSM peak and hold injectors and associated resistor box. This was fairly involved with the wireing in of the resitor box and changing the clips on the injector loom was faily involved. Lucky I love this kind of stuff so it was no problem, a little time consuming as everthing has to be soldered and taped but still all good.

Yesterday I also started looking at where to place my airfliter, I'm hopeing that I can get it over into the wing for a nice cold air intake, however I think this may be a little diffficult to make work. I am likley to relocate the battery tray over towards the wing slightly and then have the air filter next to the battery. I'll have to make that decition today.

No pics of yesterday I'm affraid but I'll be sure to get some pics today when all the exhaust fab and intercooler pipe will be done.

OK Appologies for not updating this sooner. I was pritty busy last week finishing the Turbo converstion!!.

I managed to get it all sorted and it is now all compleate. I sorted all the oil feed. The exhaust was custom fabricated by Fusion Motorsport, using the turbo flange from the USA ebay turbo down pipe (at least something usefull came of that). The exhaust was a bit of headache to fabricate as we needed to bring the wastgate exhaust in, in the least restrictive way. For the moment I am still using the old flexi pipe, cat and catback system. This is seriously under sized for the turbo and I will change this as soon as I get a chance.

I did a full service and installed colder rated NGK spark plugs. I also installed a Glowshift Boost and EGT gauge wired in and managed to get all the boost pipe plumbed in nicely. I didn't need to modify my bumper, or fogs at all to get it to fit, it is really tight but it works!

I finished the conversion Saturday late afternoon, Ed a Fusion Motorsport hooked up the laptop to the ECU and we adjusted for the new injector sizes. I cranked the engine and it started up first time . We checked for leaks and everything was good.

Luckily the guys at Surrey Rolling Road were still on site, and with a show of my puppy-dog eyes I managed to convince them to let Fusion Motorsport have a Tuning session on the rollers before they went home. After a good tune session the car was running really nicely making good strong boost and holding a good steady 5psi on just the wastegate spring. The low RPM power was hugely increased but the top end would not show any gains above 220bhp (fly). This is with out doubt because of the standard flexi and cat/ cat-back on there at the moment. The increase at low RPM is stunning at 4400 rpm my JDM H22 made 130 bhp....It now makes 170bhp !!!

So I now need to sort my exhaust and try to free up some of the top end.

I have upload a few pictures here, but there are more on facebook (I think this is a public link so everyone should be able to view them)

http://www.facebook.com/album.php?aid=5 ... cee625caa1

Ok it has been a while since I last posted so I'm finally getting round to updating this thread.

I got my exhaust sorted got; a got a custom 2.5" full system made from a mate of mine at Longlife. He did me a full 2.5" from front to back the inc flexi pipe decat with one reonator and a back box.

It has a great sound really like it and more importenly it really lets the Turbo breathe better










The difference in the turbo with the new exhaust was huge, it spooled up much faster. So much so that I needed to get the car mapped again to make sure it was getting the most from the freer flowing exhaust

So after a trip back to Fusion Motorsport and another session on the rollers the car started to make some really nice power. We keep the boost constant at 6psi on the wastegate spring. and peak power was notably increased to 240bhp with just under 200ft/lb of torque.



So this was how I drove the car around for ages, it was very capable and would pull really well through all gears. However I figered a bit more stopping power wouldn't go amiss.

So i managed to get a great deal on some accord type R callipers and disks and fitted them up along with some EBC red stuff pads....







So that's where it stopped for a while.....

A while ago I was looking at maybe having a spare engine for the car as my engine really needed some attention it was leaking oil from every orifice imaginable and really badly from the balancer shaft seals it was also overdue a camblet and if I wanted to run more boost a spare engine seemed like a good idea.

Then I noticed on here a link to an ebay sale that a guy was selling a low compression turbo engine

Spec was:
Mahle .25mm oversize low comp pistons, sleeve strength is retained by only using .25mm oversive
Block bored and honed to match pistons
Eagle rods with arp bolts
Cometic head gasket
New OEM oil pump water pump and timing belt
Crank micro polished
Block refaced
All cleaned and flushed by the machince shop before being built up.

I was never really the intention to go with a built engine and had only just really got the car set up nicely for low boost. so I didn't bid on the engine and the auction ended with no bids. I sent the guy and email explained that I had a turbo prelude, and he asked me to make him offer

So once short trip in a van later I was the proud owner of a built prelude engine

I whipped of the sump and had a look and sure enough there where the eagle rods and Mahle pistons.......very very cool indeed.

So this has been sitting around for a while, and a month or so ago decided that it was time the new engine when in. Normally I would be knee deep in oil getting stuck in with the engine transfer but due to a load of other commitments I was really struggling to find the time to do the project, so I spoke to my friends a FusionMotosport and they agreed to fit the engine for me

I needed a boost controller to use with the new engine, so that I could run more boost. I was recommended the Apexi AVC-r and managed to pick one up for a steal on ebay.

I left the car with fusion for a few days in which they swapped over the engine retaining all the ODBII sensors intake and distributer onto the new block. They fitted up the AVC-R and set it up with a good remap on the dyno...

at conservative boost 7-8psi I'm now making 274Bhp and 210ft/lb's of torque

So just to finish, I have to have my favourite picture



Cheers Nitin

Reppage!
See you around all the time mate, really is a good looking car
Must meet up for a little drive sometime, with a few more of the local lot (Nitin?)

Great build mate. Nice progressive progress.
+ Rep

SiR Si wrote:

This makes me want to turbo my lude. 210 lb/ft

Nice work Sir