1600 8v Turbo.
It gets asked almost weekly. Lots want to know about it, lots contemplate it, an TBH its not really that hard doing it. Its the "being bothered to finish it" and I simply CBA after 2 years of messing LOL!
This is exactly what I used to do mine*
*Bolted it together, but never ran it, so fook knows if it would have worked or not...
From top of engine down.
Spacer Plate:
Lowers engine compression so the added boost doesnt make swiss cheese outta the pistons.
Where from: http://www.ferriday.co.uk/cnc/decomp...n_plates.shtml
Phone them ^^ for your requirements, this thread isnt a calculation page for compression ratios, contact them & discuss your requirements, hes a very friendly chap.
I opted for a 1.3mm thick plate, cant remember off my head what the CR worked out to be but it was deemed "safe" regardless. Last time i spoke to them it was a 2 week wait & £107 + postage.
Which Charger:
Big factor, to big & it will foul the rad, to small & well, why bother (physical size) Also AR & Trim size, to big an it'll lag like fook, to small an well actually smallest is like a T2 & there pretty damn good!
DONT use a low blow Diesel blower, there on a diesel motor for a reason.
A T2, T25 maybe even a T3? I opted for a T25 from a SAAB 9000 Carlsson Turbo with @ 12 odd PSi max boost out the box (that max without tampering with it BTW).
DONT be tempted by cheap chargers, there probably fcuked! Rebuild kits are cheap, but as i found out, taking a charger to bits can be fiddly for some one with idle thumbs...
Bigger is better to an extent, BUT to big an the actuator arm rams into the back of the rad, there will more then like be no room AT ALL for the standard engine fan.
Where from: Mine was sourced from a SAAB breakers via eBay. Cost me £80 with 6 months garantee that is does "work"?
Exhaust Manifold:
The bit you really really need! You might get lucky an get your hands on an old Courtenay Turbo item, realistically, dont bank on it. Choices are (limited)...
"Log manifold" ala HondaTech stylee. DIY Civic/CRX turbo people have had superb results with these belive it or not!! BUT you need welding skills, here you basically weld a load of cast steel pipe sections together an mate them to a 8v flange borrowed from an old 4-1 manifold:
Or you can chop up a 4-1 manifold, which I also started, an this like most things, I got bored of rather quick (here my half @rsed mock up - dont use Gasless MiG either):
You can also use an MPi cast iron manifold with a funky cast iron adapter used for 200SX turbo upgrades, with a bit of machine work it does work:
Where from: SPi manifold, FOC from Adam of here. Cast steel parts came in at about £30 delivered from a gas piping specailist i found on google. Second hand FUBAR 4-1 approx say £30?? Cast Iron adapter I got from eBay America for about £55 & had £20 worth of milling work done to it so it bolts straight into a SPi manifold.
Dont forget, you'll need all the gaskets aswell, manifold to charger, elbow to charger, manifold to head etc etc.
Downpipe & elbow:
I used a T25, so needed a T2 series elbow. Mine was taken from a R5 GTT, cost £20 +postage an some late night eBay bidding. Bolts straight onto the charger. (gasket needed here - about £2)
For the downpipe, I opted for a Fiesta RS Turbo item as there slightly longer then the R5 version (I had both an measured them) longer the better (ask your mum - she'll verify that) but if its to long its easier to shorten then lengthen....
(For this excercise here's my rough as @ss holes demonstration) SAAB charger, bolted to Renault elbow, bolted to Ford downpipe, roped onto an E16 short block. You get the idea.....
Where from: eBay, price varies massively! Anything from £10 to say £50 + postage costs.
Dont forget! Once its all bolted up & into the shell, you will need to lengthen or shorten the downpipe aswell as connect it upto the exhaust system.
This is where it gets tricky, as there is NO room at all for the oil filter.....
Oil Filter Relocation:
I had to as I had no choice but to do this to forward progess....
Basically, the hot side of the charger would have been wedged about an inch into my oil filter if I didnt.
Mocal, there your best friends for this!! You cant get a small block 8v relocation kit....or can you?? Yes. You can, as I had one & it fitted fine! I found a shop on eBay selling SEH/NE ones, emailed him asking if he can supply one for a small block 8v, an yes he could, so yes he did.
Where from: eBay @ £118 + postage IIRC