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Old 09-01-2021, 09:47 PM   #251
JDwhiteWRX
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My intercooler and radiator cores arrived yesterday. I got an amazing deal on these cores from CSF, although I personally believe PWR make the best heat exchangers money can buy.

//i.imgur.com/nn7lDqY.jpg?1

The intercooler core is rated to 850hp and I am still trying to decide whether I should trim down the height of the radiator core a little before I weld on the end tanks.

//i.imgur.com/yEFywH5.jpg?1

I have a reasonable amount of space in front of the engine to fit both heat exchangers. They are most likely going to be stacked together and fully ducted with the air venting out the hood.

//i.imgur.com/u0Ws4Pg.jpg?1

So I am just playing with the angle at the moment before I make some kind of support to hold them in place.

My turbo is currently in transit from Full Race Motorsport in Arizona. I have to give a big thanks to Geoff from Full Race and Micah (Homemade WRX) for helping me choose which turbo to get.
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Old 09-08-2021, 04:53 AM   #252
JDwhiteWRX
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My turbo has arrived!

It took me a long time to come to a decision on which turbo to get, it was either going to be Garrett or Borg Warner. Obviously both great options but in the end the EFR series from Borg Warner won me over.

I've always been a fan of twin scroll housings and Garrett don't seem to be offering this on their newer G series turbos, they really do help to get a larger turbo making boost sooner.

I was also attracted to the aluminium housing option that is only available with BW EFR for the weight savings and better thermal properties.

EFR has a significantly lighter weight turbine wheel for better spool and transient response and a properly designed internal wastegate system for simplicity and better packaging.

The IWG is not always perfect though and it will limit my top end power to some degree. Full Race Motorsport have just released a kit for the internally gated EFR that uses a Civic Type R electronic IWG actuator for ultimate boost control, so I have purchased this kit to prevent any potential issues.

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Old 09-08-2021, 07:11 AM   #253
chanomatik
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Ooooohhh sexy
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Old 09-16-2021, 01:14 AM   #254
speedyHAM
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Quote:
Originally Posted by JDwhiteWRX View Post
The IWG is not always perfect though and it will limit my top end power to some degree. Full Race Motorsport have just released a kit for the internally gated EFR that uses a Civic Type R electronic IWG actuator for ultimate boost control, so I have purchased this kit to prevent any potential issues.
That is awesome. The IWG control should be amazingly good with that kit. I look forward to hearing how it runs.
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Old 09-17-2021, 12:39 AM   #255
JDwhiteWRX
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Quote:
Originally Posted by speedyHAM View Post
That is awesome. The IWG control should be amazingly good with that kit. I look forward to hearing how it runs.
Yes it's a great idea! this kit was developed and run on the car that just won Pikes Peak unlimited class.

I've spent a lot of time going back and forth with turbo position this week.
My original intention was to low-mount it just behind the shock and run the dump pipe inside the cockpit just in front of the pedal box behind a steel box enclosure then out the side.

This turbo is much larger than I thought so it does not fit in that position. I then tried to high-mount it and I did manage to make it fit but it goes against everything I've been trying to achieve with this build. The main goal is to move all the weight as low as possible and toward the center of the car.

The only remedy is to move the shocks. It will be a lot of extra work and I will have to cut off the shock mounts that I have already spent a considerable amount of time making.

This photo shows the rough position of the turbo and also the rough position the shocks will be moved to.

//i.imgur.com/BNhiW14.jpg?1

You can see the weight is low and back, the tradeoff is the shocks are now mounted higher up but they are also further back which is good. The shocks weigh 2.6kg (5.7lbs) each and the turbo weighs only 11.15kg (24.6lbs) with its aluminium core so there is benefit to mounting the turbo lower than the shocks. Generally speaking a low-mount turbo is also better for heat management.

This new shock arrangement should also allow me to mount the front swaybar behind the engine.

I have been waiting on some things to arrive before I could settle on a final mounting position for the turbo as there are potential clearance issues with the steering intermediate shaft. I bought a complete steering column from a wrecked 86 and I will be running a motorsport sytle collapsible column from the EPAS unit up to the steering wheel which is moved a long way back from the stock position.

I have already trimmed all the unnecessary bits of the EPAS.

//i.imgur.com/EUpK9fT.jpg?1

The other consideration is the turbo manifold which I am going to try build myself. I ordered a really nice 347ss DIY manifold kit from Hypertune which also includes a beautifully made T4 twin scroll cast collector to suit the IWG turbo. The collector is a critical part and sees the most extreme conditions so buying one like this seems the best way to go.

//i.imgur.com/2UEQ6C8.jpg?1

Since Hypertune don't support Honda engines the kit is actually for a Evo but I can grab any extra bends I need from them if required, they are not too far from my house. I also had to grab a head flange from Mazworx for this reason, its CNC ported already so the holes go from oval to round.

//i.imgur.com/pgHssS4.jpg?1

I don't have a lot of time to work on the car right now as we just had a baby girl but I'm collecting all the parts for when I do get more time.
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Old 09-23-2021, 07:01 AM   #256
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I've finished moving the inboard suspension. The shocks have been moved from the original position to make space for low-mounting the turbo. Many new positions were trialed before settling on this final position.

This is where the shocks will sit now

//i.imgur.com/lP5qljw.jpg?1

You can clearly see the space that is now open for the turbo

//i.imgur.com/0P1otwT.jpg?1

I was able to use the knowledge gained from the original design to make this a relatively quick process. I went through the whole process again that was previously described in this thread to build a mock up shock and measure the wheel travel versus shock travel and calculate the rising rate of the suspension.

This video shows the new design in action

https://www.instagram.com/p/CUHmYInP..._web_copy_link

The original shock mounts were cut off once I was happy the new design would work.

//i.imgur.com/48jmNeE.jpg?1

//i.imgur.com/Xi1JifS.jpg?1

Now I have been able to properly low-mount the turbo with plenty of clearance to make my turbo manifold and no more issues with the steering intermediate shaft being in the way.

//i.imgur.com/RP9jY9R.jpg?1

//i.imgur.com/UZeF0t5.jpg?1

I am both excited and nervous to make my very first turbo exhaust manifold now.
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Old 09-23-2021, 08:33 AM   #257
whozatguy
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Awesome, great work on the suspension layout. Very cool to see the system in motion.
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Old 10-07-2021, 05:27 AM   #258
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For those not on Instagram here is a sneak peek of the turbo exhaust manifold fabrication.

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Old 10-09-2021, 05:32 AM   #259
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More progress on the manifold, finished making the runners and tacked it all together for test fitting on the car.

It's been a challenge for sure but I'm very happy with the progress so far!

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Old 10-09-2021, 03:50 PM   #260
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Still loving the build. Looking to snag a BRZ of my own now.

Last edited by Homemade WRX; 10-14-2021 at 08:41 AM.
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Old 10-09-2021, 04:00 PM   #261
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Quote:
Originally Posted by JDwhiteWRX View Post
More progress on the manifold, finished making the runners and tacked it all together for test fitting on the car.

It's been a challenge for sure but I'm very happy with the progress so far!

edit: nevermind. Looks like you have the cylinder pairing correct. I just got a little cross-eyed.
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Old 10-12-2021, 10:58 PM   #262
ether947
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Quote:
Originally Posted by JDwhiteWRX View Post
I've seen that option from AGT Engineering but its rather expensive for what it does. I'm hoping my standalone ECU can control it otherwise I'll try one of these https://www.ebay.com.au/itm/14403228...53.m1438.l2649
FYI, I bought one of those EPAS controllers from eBay and so far it works as advertised. I haven't done any hard driving with it yet but I don't think that should be an issue.
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Old 10-12-2021, 11:27 PM   #263
K3rm1tth3fr0g
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Quote:
Originally Posted by JDwhiteWRX View Post
My turbo has arrived!

It took me a long time to come to a decision on which turbo to get, it was either going to be Garrett or Borg Warner. Obviously both great options but in the end the EFR series from Borg Warner won me over.

I've always been a fan of twin scroll housings and Garrett don't seem to be offering this on their newer G series turbos, they really do help to get a larger turbo making boost sooner.

I was also attracted to the aluminium housing option that is only available with BW EFR for the weight savings and better thermal properties.

EFR has a significantly lighter weight turbine wheel for better spool and transient response and a properly designed internal wastegate system for simplicity and better packaging.

The IWG is not always perfect though and it will limit my top end power to some degree. Full Race Motorsport have just released a kit for the internally gated EFR that uses a Civic Type R electronic IWG actuator for ultimate boost control, so I have purchased this kit to prevent any potential issues.

I have seen and heard lots of issues with the IWGs on the EFRs not working correctly even when properly configured with BW not being able to provide any meaningful support or resolution.
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Old 10-13-2021, 11:57 PM   #264
JDwhiteWRX
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Quote:
Originally Posted by ether947 View Post
FYI, I bought one of those EPAS controllers from eBay and so far it works as advertised. I haven't done any hard driving with it yet but I don't think that should be an issue.
Thank you very much for letting me know, much appreciated.

It looks like I will be getting a Haltech Nexus for this car so I think I should be able to drive the EPAS with that but otherwise its great to have options.

Quote:
Originally Posted by K3rm1tth3fr0g View Post
I have seen and heard lots of issues with the IWGs on the EFRs not working correctly even when properly configured with BW not being able to provide any meaningful support or resolution.
Same here, I think they can be resolved with the Turbosmart actuator but this electronic actuator I'm using should work perfectly.
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Old 10-14-2021, 01:29 AM   #265
K3rm1tth3fr0g
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Quote:
Originally Posted by JDwhiteWRX View Post
Thank you very much for letting me know, much appreciated.

It looks like I will be getting a Haltech Nexus for this car so I think I should be able to drive the EPAS with that but otherwise its great to have options.



Same here, I think they can be resolved with the Turbosmart actuator but this electronic actuator I'm using should work perfectly.
Go in the borgwarner thread on here. The issue I am talking about is when using the upgraded actuator.
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Old 10-14-2021, 08:43 AM   #266
Homemade WRX
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Quote:
Originally Posted by K3rm1tth3fr0g View Post
Go in the borgwarner thread on here. The issue I am talking about is when using the upgraded actuator.
I know that the brackets had a deflection issue and that with pneumatic gates, boost tapered off hard...like they couldn't hold.

What was the cause?

The electric actuator should be awesome on it, provided deflection is eliminated.
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Old 10-14-2021, 10:49 AM   #267
K3rm1tth3fr0g
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Quote:
Originally Posted by Homemade WRX View Post
I know that the brackets had a deflection issue and that with pneumatic gates, boost tapered off hard...like they couldn't hold.

What was the cause?

The electric actuator should be awesome on it, provided deflection is eliminated.
No idea why the wastegate arm was bending but I saw it noted by multiple folks with IWG BW kits and it was not solved by upgrading the IWG.
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