It's been in the works for a long time(actually sent the longblock to PG back in NOV), and things are finally starting to arrive.

The turbo arrived today;






Garrett GT35-82, Four inch ported compressor shround, .82 AR turbine, and three inch v-band discharge. I didn't use the mazda specific turbo because I want the full 4" inlet(which is not possible using the stock turbo placement), and I don't like haveing to work with the turbo behind the block..

I'll be updating this thread as more parts arrive and my build progresses.

There are so many eye'n the 35 series now. Congratulations! I still want a 3071.

Look at the size of that monster!

Geez, I'm really jealous. Congrat and keep the pics coming.

i got a 3582 on my rx7, but i wouldnt put it on my speed6. but if it is your only car, and want it to go fast as possible, i guess do what you do....

I'll definatly keep everyone posted as new parts arrive....




I was originally looking at a smaller turbo, but I just seems like a larger turbo is better suited to the limitations of our motor and to direct injection as well.

The extreme load placed on our motor by fast spooling turbo's coupled with the HDFP's inability to maintan/produce adequate fuel pressure at lower rpms, is just asking for trouble. I decided on the gt35 because it should move the powerband high enough that the HPFP should have no trouble keeping up, and I won't have to worry about part throttle boost causing the lean conditions that I've seen when tipping into the throttle. I'd much rather have safe lag(and the inability to produce significant boost at part throttle) contributing to better gas mileage, than instant boost contributing to a grenaded motor...And I'd like to make about 550hp lol.

Will that mate up with the stock exhaust manifold?

Where are you mounting the wastegate?

Carlos at CPboost is making manifold for me.

It will situate the turbo and wastegate similar to the manifold he makes for the N/A mazda 2.3, but the placement will be changed slightly to clear our alternator.

It should be very similar to this manifold:



I will be using a tial 44mm wastegate.

The TRUE build a beast has arrived.
Nice project man, love the anti surge machining on the housing of that monster gt35.
Are you planning on running a manual boost controller?
What about Cams...seems you've come this far.
Are you running stock compression?

Very smart way to deal with the low end issues we have......it should feel like an afterburner at about 5000 rpms:)
Good Luck!

The machining looks very nice in the pictures; it's not near as pretty in person(looks like they used a drill press, not a CNC machine), but two different shops local to me said that they are fine, and will not effect the perfomance at all. Boost will be controled by the wastegate around 15psi until breakin is over, after that I'll use the stock solenoid with the standback in control. Eventually I'll add some cams, but there aren't any out there right now. The motor was built by PG to thier specs, it's listed as half a point lower compression than stock with arias pistons and pauter rods, the head was rebuilt and fully ported, and some arp headstuds and the cosworth BSD kit finish it off....It's not here yet, but is almost on it's way back to me after a LONG time at PG...

You will need to add another vacuum line to the cold side of that turbo if you want to use electronic boost control. may want to consider an adjustable wg so you can dial the boost in that way. BTW what is your target boost once all is said and done?

I think we're going to tap the compressor outlet for the boost reference. I'm not in boost much in day to day driving so I think 1.3 bar on the street should be fun, and as much as tuning will allow on race fuel.. The wastegate will be set somewhere around 1 bar .

Any plans on beefing up the axles? All this power will def make them snap.

I hate you. I'm sure other members will agree. We all hate you.

=)

Edit: And I mean that in a very loving way.

Why does the turbo in the picture say AR .70 when you say it's AR .82?

I don't know yet, but the driveshaft shop is only a few hours away. The budget doesn't allow for them right now, but I'm sure they be needed eventually.



It's ok. My wallet hates me right now too, so does my savings account--and my mouth(I had all 4 wisdom teeth pulled today, ouch).





The compressor AR is .70, and the turbine AR is .82.

Most manufacturers don't let you change the compressor AR as it doesn't have much effect on the flow. The turbine AR on the other had has a big effect on the spool up and the top end flow potential. I chose .82 because it should spool fast enough to peak right at our motors torque peak, but still flow well enough on the top end to hit above 500 hp, I could have picked .63 to increase spool up, or gone with 1.06 to raise the top HP potential but at the cost of a much later spool up..

wow, I was just looking at the 35 prices. Actually going your route, w/ custom manifold and DP seems like a great way to go. Not cheep or antything, but saves you some money to get the custom manifold and DP. I am interested in seeing that sturff.

Yeah, it's not the chepest way to go, but it's really not that much more expensice either, my turbo manifold and wategate are about $2800, plus a few hundred bucks for a custom downpipe. The atp kit plus an unpgaded manifold will set you back about $3000~3150 depending on what manifold you buy, and your still left with the shitty stock turbo placement, and an internal wastegate...

There are alot of nice products coming out right now.. I hope to see alot more custom/DIY setups now that things are starting to come togeather for this platform.

Also, I'll be selling my DNP manifold(tapped at the collector for an EGT), and CP-E downpipe when the car goes into the shop. Will also be selling the stock turbo, but two of the stud holes are stripped and will need to be drilled out and retapped-or you can just use bolts and nuts on those two corners like I am currently...

Let me know if anyone is interested...

it looks great, i may have to copy your setup when its done, im very inpressed

Thanks, I appreciate the comments.

Another package arrived today, and unfortunatly they sent the wrong product, I ordered the boost a pump, they sent the boost a spark. I called them and went right to a machine, so it looks like I might have some trouble trying to get them to send the product I actually ordered...


I got some good news from Carlos today though. He said the manifold turned out great and he should have some pictures for me to post up tomorrow. He is going to be selling the manifold for ~$850, plus $140 for ceramic coating. I'll get those pictures posted as soon as he gets them to me....

yikes - that includes the custom DP though too, right?

if it does, im game, if not then i will make my own

That does not include the DP, but he will be selling a DP seperate for ~$200, plus $100 for the ceramic coating..

That price is pretty reasonable for a custom manifold, the two shops local to me wanted $1000+ for just the manifold, with no ceramic coating..and I had to provide the head flange..


Pictures are in:

Wow.... SS it looks like you will have a KILLER setup here..... can't wait to see how it turns out!

Wow! Looks better than I thought it would. I see he crammed the wastegate way down in there right next to the firewall. Prepare for all the funny wonderful noises of an external wastegate.

Thats all I have to say

Oh yeah, I love the way an external wategate sounds on the top end when it's venting. It will probably be a strait dump..

*boner*

nice work!!

mani came out great IMO.

im looking forward to the completion of this project...for a couple of reasons. lol.

more pictures:

Is the DP catted? How much are you looking to get for it?

CP-E DP is not catted, tapped near the bottom for wideband 02, $400 plus shipping.
DNP manifold, tapped in the collector for an EGT, $400 plus shipping.
Stock turbo, needs new studs(two will have to be retapped larger), $250 plus shipping.

All of this is still on the car (which is at the dealer getting the steering rack fixed). I can get picutes of all of this if anyone is interested..

If you were asking about the DP Carlos is selling with the manifold, it is not catted...

For $200 it's definately not catted.

One more picture:

Turbine housing has been removed and sent off for ceramic coating.

About ~1290 for DP+Manifold Coated? That is an AMAZING PRICE! Only thing left is turbo and wastegate! wow.. Not bad!

PLEASE run open WG. You will be the sickest sounding Speed6 on the road when you hit boost!

That's the plan!

Here are a couple of pics of my parts now that they are ceramic coated:

You just became my least favorite person on the planet!


J/K looking good!

is that like a V-band flange for the EWG?

Yeah, I'm going to run a tial 44mm external wastegate and it uses a vband for the inlet and outlet..

Another part installed.

please do tel about the boost a pump. Im not sure if ill need it or not.

DOHHHH. That's my manifold. God I am going to miss that car. You will enjoy this manifold. I made 432whp out of a regular mazda3 (fully built of course) with that manifold and a gt35r. With all wheel drive, direct injection, and much better cooling properties I think you will see that if not more power (given the drivetrain loss)

I havent really played with it much yet. It's installed at the lowest setting with a 5psi pressure switch. At 5psi You can set it to send between ~14 and ~17.8 volts to the fuel pump. According to kenny bell's testing the average pump wil flow almost 59% more fuel at 17.8 volts. Right now I have it all the way down so it's just holding 14v at the pump.. If I start to see a pressure drop on the standback, I'll adjust it up. I've got the Mrlilguy HPFP on order so, the Boost-a-pump is just there to make sure the intank pump wont become a problem at high power levels. It's just in there for piece of mind right now...

You took the easy way out! LOL!

Yep, I remember all the BS you went through trying to get that walbro to work. I don't want to deal with any of that crap, this should flow plenty for my short term hp goals.
By the time I'm ready for more someone should have a pump available, and I'll just use the boost-a-pump with it...

More pictures because I'm bored. lol.

Good news though, my motor, head and the spec clutch are in transit here from PG, hopefully Fed-ex freight doesn't take forever and the car can get into the shop sometime next week..

The motor is here!



Couple of pics of the porting in an exaust port. I'll get some more pics when I unwrap the full motor.




Work on the car starts next tuesday! I will be sending my stock flywheel off to Fidanza so they can get the lightened part made, that's going to take a 3~4 weeks, so I expect the car to be apart for six to eight weeks.