Update- June 27th 2009 - Build Starts tomorrow!

It has begun!

I'm collecting parts for a custom build and figured I'd start a thread so you guys (and myself) can track my progress. I'll be building a front/top mount setup from scratch. My goal is just over 300HP with room to grow when I want more(when I upgrade ignition and injectors). I'm going to be doing all the welding and machine work myself (just got a fresh tank of Arg/CO a couple hours ago ) I've ordered the exhaust manifold flange from Mazdatrix and will be building a custom manifold with that. While I would like to do something along the lines of an equal length tubular header, I will probably end up just doing a straight tube manifold like the PTP one.

For parts I will be using some Ebay stuff( I know, I know) for less critical stuff. But wont be cheaping out on the more important things. I'm still shopping for good deals on some of these parts to trim costs. I still have a few things from my last boosted vehicle (boost guage, catch can). So here is my initial parts list and status on each part.

MM Cobb AccesPort--------------------------------------- ( Bought form RevLimitLaunch)
BNR T04E 60-1 P trim 1.00 Divided --------------------- (Arrived)
Synapse Synchronic 50mm Adjustable Wastegate ---- (Arrived)
Ebay RFL BOV and flange pipe -------------------------- (Arrived)
Manifold flange from Mazdatrix ------------------------- (Arrived)
Assorted 3" and 2" pipe straight/bends ---------------- (Arrived)
Ebay intercooler and piping kit -------------------------- (Arrived)
AEM wideband and guage ------------------------------- (Arrived)
Various flanges, hoses, gaskets ------------------------(arrived)



-Edit- Upgraded to BHR Ignition, 900cc P2 injectors and a HKS SSQV BOV

Keep in mind on this price sheet that it includes enough pipe to make a new 3" midpipe and exhaust system. Bought a Borla XR-1 Race muffler 3" in/out for the midpipe. Will probably put some kind of resonating tips on the back.

Any input, advice or suggestions is welcome and appreciated

--Pictures added June 15th!--

 

I wouldnt recommend an eBay BOV. Thats a pretty important piece of the setup and if that thing doesnt open, youre gonna surge the compressor. But if you really want one, I have an eBay BOV type RS if you want it. It came with the turbo kit I bought used but upgraded to a real Greddy type RS. They look very similar. Seller said it had less than 1000 miles on it. Will sell it for $25 shipped if you want it.

 

Is that a ball bearing turbo ?

 

Thats one of those parts I'm on the fence with. I ran one on my Procharged Vette for a long time without issues, but I know the turbo is a bit more sensitive to surge. I'm keeping my eye out for a good deal on a Tial or Greddy BOV. I"ll keep your offe rin mind though

 

Cool, ya man, just let me know. I got my Greddy on eBay for $150. Not bad since most stores are selling between $170-220.

 

I love my wife

For a little backstory. My wife has watched me supercharge a C5 vette and spend countless hours and large sums of money repeatedly rebuilding the obliterated driveline. I still have corvette pieces and parts littering my garage. So I was dreading her reaction to my plan to boost another car.

Until yesterday I hadn't told her my plan to boost my Rx8 yet, but she took note when I bought a new welder and an 80cf bottle of shielding gas for it. She asked me last night what I needed the welder for. So I told her "to turbo the Mazda". She rolled her eyes and gave me that "uhg..not again?!" look. She seemed annoyed the rest of the night.

Fast forward a few hours to today. She has accepted it and is even asking questions about what it will look/sound like ect. And even better, she is at this moment sitting at a computer next to me in my office looking for a body kit for my car.

Update:
My Accessport arrived today!(Thanks RevLimitLaunch! ) So now I can spend the next few days playing with that while I wait for my pipes to arrive.

 

Dang dude. You're a very lucky man. Does your wife have a sister? :P
And I'm subscribing to this thread. I love watching custom builds!

 

nice!

 

Ha, ya man, I kinda got the same thing going on. But I told my wife on the very first date that I am obsessed with cars and they are a huge part of my life and if you cant deal with it, then lets just go our separate ways. She agreed and things are great. I tell her everyday all the things Ive been buying for the car and she says, "Cool, cant wait to help you work on it then go for a ride!" Ya, life is good!

 

So .................. no rug rats in your house then ?

 

Damn, nice build.

Subscribed.

 

+1 subscribed also. cant wait to see what you do lol

can you make it a diy haha step by step by step jk

 

I dont know about a step by step, but I can take some pics along the way for updates

Update:
-Ordered BOV-

 

Negative, just the one in the garage!

 

I have to throw money at my wife to keep her cool with my car stuff. HAHA! As long as she has money to blow on what she likes we are good. I have 10 vehicles now and she will not allow me to sell anything. I need to really sell some of it but everytime its, "well this is the car you had when I met you" or "we drove from our wedding in this one" or "this is one of the cars that I can drive". I have heard stuff like this for every damn vehicle I have. lol

 

LMAO!! Ya, its funny how that works with girls. Take $100 bucks, get a new purse or something!! Lol! The car I had before the 8 was a Saturn Ion Redline, (same as a Cobalt SS, just Saturns version) and that was the car I had when I met her. Then about a year later, she bought one, so we had 2 in the family. Then when it came time for me wanting to get the 8, she was complaining that its "cute" that we both have the same car and now things will be different! Oh well, I bought the 8, she fell in love with it, had problems with her car and sold it, so now we dont have any Redlines!

 

Ordered a few more parts.
I am now on Bryan's(BNR) Turbo build list.
Also trying to track down a shop locally that can bend 3" pipe for me. If I can find a place to make some tight radius bends in some of my pipe I'll have a go at a more exotic manifold.

 

Cool , might i ask why your going with a top mount set up though?

 

Well, firstly is cost savings. The cheapest kit available would be a used greddy kit, and that wont meet my goals without more money thrown at it in upgrades. My current cost sheet shows roughly $2500 though I expect it to go closer $3000 when all is said and done. This setup should make the same or more power than a greddy setup even at conservative boost levels. And when I do want to make more power I can just turn up the boost. After I upgrade coils, injectors, clutch, ect of course

Secondly, since I'm going to weld up my own manifold, I might as well put the turbo out front to give myself lots of room to bolt on whatever turbo I want. None of this silly "what can I fit on the greddy manifold?" nonsense

Lastly...ok, bling factor. If I'm gonna put my sweat, blood and a couple grand into a turbo setup, I want to be able to pop the hood and show off my work

 

wow nice to see you got a wife that accepts what you do
good luck with the build!

 

Parts will start arriving this week. Going to try to get the battery relocated to the trunk at least.

I have the car up in the air tonight just to eyeball some of my clearances and start plotting stuff out in my head. I've decided I wont be attempting anything fancy with the manifold. Its just too tight in there and i think it will just lead to wasted time and materials.

I am now debating how I should orient the turbo. A big factor is that I intend to stick with a draw through MAF setup(maf before compressor). And since I am tuning with the AP I know this is tricky. If I do it like the PTP setup I have to put two 90 degree bends in the intake while still getting enough straight pipe on either end of the MAF. I'm wondering though if I cant aim it more like the Esmeril setup and go straight into the bumper with the filter(MAF in the middle). Any opinions on this ?

 

https://www.rx8club.com/series-i-do-yourself-forum-73/diy-battery-relocation-trunk-173180/

incase you need some ideas on how to do the relocation. im sure you got it all down but just tryin to help out lol

good luck cant wait to see how it turns out bro. wish i knew how/had the money to do a turbo build...maybe one day

 

Great write up, thanks for the link!

 

Moved my battery to the trunk today. Put it in the far back passenger side corner. Amazing how much room that opens up under the hood.


Also a few parts arrived today. Got my BOV and adapter pipe, Mazdatrix header flange and the 15' of 3" straight pipe for hot side/exhaust.

I think the 3" may be slight overkill Not seeing how I will fit all 3" down through the engine bay. I still have to find some 2" at least for the primaries and maybe go 2.5" for the rest of the header. I'll at least try to use the 3" for my downpipe and that will leave plenty of the 3" left over for a custom exhaust system

Edit- I've ordered some 2.5" piping for the header. It looks like I can make it work for the primaries and main tube.

 

so your basically piecing together your own turbo kit?

how do you know what all you need? i would love to turbo my car but i dont know anything about it...never done anything like that to a car. the most i have done was install a catback and intake all on my own on my rx8 (the only car that i have ever modded) i would love to start buying the pieces to put one together but i just dont know where to start.

where do you get the specs for the pipe diameter. aswell as what angles they need to be bended what needs welded together if any.

where do you get the parts of a turbo piece by piece i know i can get the BOV and others. sorry if this is really broad lol just figured id ask you since your doing this on your own

and i have been researching like crazy on turbos i printed of the pdf file of the greddy turbo install just to read how it was done i got pictures of all the parts included but its vague no part numbers or sizes.

if you dont mind helpin me out a little that would be cool

and if you would rather pm me instead of explaining it on the thread thats fine i dont wanna get away from the subject of your turbo thread

i really hope i dont get flammed for this lol im always so worried about asking questions on here because of that lol

dont wanna lose my street cred HAHA............................................jk