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Underbody braces, turbos and more!

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PostPosted: Mon Oct 10, 2005 7:53 pm 
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Location: Kenosha, WI
Well, I thought I would start a thread on my budget, home made, turbo on my 1993 G10 TBI M3TRO.
If this works, great. If not, you will know what not to do.
My main goal here was to spend as little money as possible, but not get too cheap. This being my daily driver and considering I have a 1990 Mustang 5.0 for a toy and I am restoring a 1965 GTO, cost is a major concern. But besides being cheap, I am also gaining experience in fabrication and welding.
All the fabrication and test fitting is being done on a spare G10 on my engine stand in my garage. So far the goal is to have all fabrication done and parts purchased so it can be transfered onto my car in one weekend.
Here are the specs so far:
Car: 1993 1.0L Geo Metro 5-speed with mods.
Turbo: Small RHB 5 Turbo with internal waste gate.
Manifold: Home made log style exhaust manifold
Intercooler: Mk1 mounted in front.
BOV: 1st Gen DSM
Intake: Aluminum TBI pressure hat.
Fuel Management: Inline Potentiometer on coolant temp sensor using an adjustable pressure switch.

So far, the manifold is done except for drilling a port for the EGT sensor. I then test fitted the turbo to the engine. I needed to come up with a down pipe to hook to the cars exhaust. I marked where the stock exhaust manifold ended and made a down pipe that ended in the same spot that should make the exhaust connection easier. I made the down pipe out of a 2" mandrel 90* bend and a straight piece of 2" pipe. I will let the pictures speak for themselves. All that is left is to weld in a bung for the O2 sensor.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


Last edited by M3 on Wed Nov 16, 2005 4:27 pm, edited 2 times in total.

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PostPosted: Mon Oct 10, 2005 8:28 pm 
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right on dude...its coming along. Funny to see someone else turboing a 93 metro 1L... thats what mine is. cheers to the work so far though dude. keep it up.

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Tim
MT Motorsport
www.mtmotorsport.ca

Mk1 3cyl - 185whp/150ftlbs - 1/4mile 13.97@103mph


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PostPosted: Tue Oct 11, 2005 9:14 am 
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The mad quebecer
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Isn't the compressor coming right into the right frame rail? How are you going to install a filter?

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PostPosted: Tue Oct 11, 2005 9:25 am 
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Jardamuth wrote:
Isn't the compressor coming right into the right frame rail? How are you going to install a filter?


From my measurements, the compressor will actually be just to the right of the passenger side headlight (when looking from the front of the car). The air filter will be a clamp on K&N breather filter.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Tue Oct 11, 2005 9:11 pm 
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Location: Illinois
I dig it. I really like the wastegate exit, that will work wonderfully.

Is your car a 5 spd or auto?

Does the TBI fuel pressure regulator get a reference signal by chance? Do you have a method to increase pressure under boost? The pot you're installing won't cut it.

What is your target HP level? Did you try to match a turbo to it?

Are you going to have a method to retard timing under boost?

(I've GOT to leave this site immediately, I'm getting ideas about the Metro I'm supposed to leave alone.)

Because of YOU, I have spent more than I should have on the front brakes. (Thanks for the pictures).

More Karma for you.

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1993 Metro XFI w/ Turbo Buick V6
9.27 @ 154

1992 Metro daily driver


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PostPosted: Wed Oct 12, 2005 9:12 am 
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Metro SS wrote:
I dig it. I really like the wastegate exit, that will work wonderfully.

Is your car a 5 spd or auto?

Does the TBI fuel pressure regulator get a reference signal by chance? Do you have a method to increase pressure under boost? The pot you're installing won't cut it.

What is your target HP level? Did you try to match a turbo to it?

Are you going to have a method to retard timing under boost?

(I've GOT to leave this site immediately, I'm getting ideas about the Metro I'm supposed to leave alone.)

Because of YOU, I have spent more than I should have on the front brakes. (Thanks for the pictures).

More Karma for you.


Let me see if I can answer all these.

My car is a 5-speed.

The TBI FPR is on top of the throttle body and has an internal manifold vacuum signal. Hopefully when under boost, it will close and raise the fuel pressure. It has been said that the stock fuel management can handle up to 5 psi. Extremerider did the CTS mod using the POT and had plenty of fuel for 10+psi.

No methods for retarding timing. Just listen for detonation. Also heard that the CTS mod retards the timing too.

As for HP level....no real target, just want it to be faster. Turbo was given to me by a friend and after looking at a crude compressor map and talking to Jarda, it looks like it will work.

I hear you about trying to leave the car alone. I can't figure out why I would rather mod my Metro than my 5.0 Mustang. :dunno:

Thanks for the Karma.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Wed Oct 12, 2005 6:55 pm 
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Location: Bradenton
I feel sorry for your oil filter..


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PostPosted: Thu Oct 13, 2005 3:41 am 
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M3 wrote:
Also heard that the CTS mod retards the timing too.

Here's the graph for the 1992 1.3L SOHC Swift. It's not exactly linear.

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1994 Metro - MPH project (getting a DOHC G13B)
1994 Metro - MPG project (getting an XFi G10)
1992 Swift - Parts car (gone)
1991 Swift - Parts car (gone)
1990 Swift - Parts car
1997 Metro - Parts car (gone)
1993 Metro - Parts car
1989 Swift GTi - Parts car
1998 Metro - Parts car


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PostPosted: Fri Oct 21, 2005 8:49 pm 
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Ok a little update. I installed the O2 sensor bung and EGT sensor fitting. I also tried out my K&N air filter I bought off ebay. I also drilled a hole in the oil pan for the turbo drain. I have to get a longer piece of 1/2" conduit to weld into it.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Tue Nov 08, 2005 10:12 pm 
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This is it! Operation Budget Boost is a go. I will start the install Thursday (Nov. 10th) and hopefully will be boosting by the weekend. I think I have 98% of the parts I need. Today I painted the manifold with some VHT high temp header paint after sand blasting it. The oil pan has the drain tube welded in. I purchased some hose couplers for the IC pipes from Home Depot. The IC is a Mk1 Sprint Turbo unit (thanks SprintDan) that I will be mounting in front. I will post pics of the install as I get into it.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Tue Nov 08, 2005 11:45 pm 
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Hope it goes well! Looks great! :D

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"daddy's car vroom vroom"
My garage.......http://www.teamswift.net/garage.php?mode=view_vehicle&CID=103
My personal gallery....http://teamswift.net/gallery/album.php?album_id=242
Currently driving a 1996 Geo Metro 1.0L
Mods coming...............


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PostPosted: Wed Nov 09, 2005 10:42 am 
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Location: trinidad, W.I.
love the setup,
i really like the downpipe, i'm thinking of doing something similar.

i read somewhere that if u can prevent the exhaust from the wastegate port from interfering with the airflow through turbine blades it will spool quicker. two separate pipes were used for each and the pipes met further down in the exhaust.( i think the TD04 down pipe is similar?)

my down pipe wasn't going to be to that extent , will be very similar to yours, but i'd like to put a divider to separate the exhaust gas from both exits.

just a simple addition if you think it's worth it.

again, i hope it goes well. best of luck!!


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PostPosted: Thu Nov 10, 2005 3:06 pm 
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that's cool! 8) karma for the effort.

did you decide not to use the JDM cast manifold?

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1991 Blue Geo Metro Convertible highly modified 1.0L Turbo3 5 spd. - 1991 Red Geo Metro Convertible customized with a Twincam 5 spd.

My Turbo3 Project
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PostPosted: Thu Nov 10, 2005 3:15 pm 
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t3 ragtop wrote:
that's cool! 8) karma for the effort.

did you decide not to use the JDM cast manifold?


Thanks for the Karma.

I am trying my manifold first. The JDM is a back up or maybe I will use it to turbo my dad's vert.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Thu Nov 10, 2005 10:41 pm 
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Here is how far I got tonight in a span of 3 hours. Installed new oil pan and gasket. Installed exhaust manifold, oil feed fittings, and TBI bridge (to mount pressure hat). The last picture was just a quick mock up of the turbo, pressure hat, BOV and IC. I will need to cut the elbow on the BOV and rotate it so the BOV faces to the side. Also, I will need to find a way to mount the IC. So far so good.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Fri Nov 11, 2005 6:51 pm 
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M3 wrote:
Here is how far I got tonight in a span of 3 hours. Installed new oil pan and gasket. Installed exhaust manifold, oil feed fittings, and TBI bridge (to mount pressure hat). The last picture was just a quick mock up of the turbo, pressure hat, BOV and IC. I will need to cut the elbow on the BOV and rotate it so the BOV faces to the side. Also, I will need to find a way to mount the IC. So far so good.


Nice Progress, and looks clean too,

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PostPosted: Sat Nov 12, 2005 1:43 am 
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The IC in the pic is off an MK1 T3 so the size should be right. I just didn't if you knew what it was off of. By the looks of one of your pics it shows the you hooked up the EGR on the exhaust mani. I don't think the intake side of the EGR is going to like seeing boost. Look into that I may be wrong.

DAN


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PostPosted: Sun Nov 13, 2005 9:42 am 
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Ladies and Gentlemen,

We Have Boost!

After thrashing on the car all day Saturday, I am now boosting 5 psi and loving it. This thing is awesome. Had to work out a few bugs at first such as the pressure hat seal blowing out (ended up modifing the stock air cleaner rubber seal to work) and reworking my vacuum check valve tee for the MAP sensor. Everything else is holding up fine. I have plenty of fuel, thanks to a pressure switch turning on the CTS mod, and EGT's are pretty low. Boost comes on pretty quick and with the waste gate arm set at it's longest length, I have 5 psi steady. Increasing boost will not be a problem when I feel the need to. Here are a couple of pics, there are more in my gallery. And now if you will excuse me, I'm going for a ride. :)

A BIG Thanks to all the people I talked to, who sold me parts, and gave me advice, and answered my questions.

BTW: I left the EGR hoses alone and everything seems to work fine. I did disconnect and plugged the hose going to the emissions canister.

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M3----"M" body "3" cylinders.
Now Turbo'd

"M3 like the BMW?"
"No, like the Gillette razor."


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PostPosted: Sun Nov 13, 2005 10:49 am 
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congrats on the build up, looks like your gonna be havin some fun in the near futture:P


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PostPosted: Sun Nov 13, 2005 12:57 pm 
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Videos, now we need vids!! Looks great by the way, is that non intercooled?

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PostPosted: Sun Nov 13, 2005 1:28 pm 
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I do believe it is intercooled. If you look in the bottom picture above you will see the top of his intercooler right below the turbo and downpipe. It looks like he is using an IC from the MK1 T3 with the BOV blocked off.

_________________
"daddy's car vroom vroom"
My garage.......http://www.teamswift.net/garage.php?mode=view_vehicle&CID=103
My personal gallery....http://teamswift.net/gallery/album.php?album_id=242
Currently driving a 1996 Geo Metro 1.0L
Mods coming...............


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PostPosted: Sun Nov 13, 2005 2:14 pm 
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how much did you end up spending on this project?


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PostPosted: Sun Nov 13, 2005 8:02 pm 
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awesome dude. U get the injector yet? Dont run anymore then 5psi with the stock injector. It does start to run lean in the higher rpms. What spark plugs are you running? I believe the stocks are an NGK 5 series. Definitely through in a colder plug. NON projected tip aswell. Run a BR7ES.

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Tim
MT Motorsport
www.mtmotorsport.ca

Mk1 3cyl - 185whp/150ftlbs - 1/4mile 13.97@103mph


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PostPosted: Mon Nov 14, 2005 1:11 am 
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what injector can we get to upgrade the one that comes in out TBI? Where do you get them from? And what cc is ours rated at and the upgraded one rated at.


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PostPosted: Mon Nov 14, 2005 6:29 am 
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Excellent job, M3! It's frustrating having to sit here and wait on my turbo project's parts, and this isn't helping! :razz: You earned it, now go have some fun!


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