Thread: How to build a 300 WHP/Liter SR (on the cheap?) discussion.

So O2 induction manifold or make one using the O2 unit as a good example to copy/improve upon. Check.

Exhaust manifold I'm thinking would be best to make as well. Here's were I believe we can have a lot of fun. I'm sure split pulse is on everyone's mind and is a absolute if you ask me. With a power goal of 480 WHP a GT3076 could be in order, but I'm having trouble thinking of one that is split pulse. Anyone? The Holset HX35 is split pulse I believe, and flows a bit more I believe, more like a GT35. This is also an option, and keeps costs quite low (don't give me any diesel turbo exhaust temp BS). Then there's the twin turbo idea. At first when I was thinking 600 WHP from a 2 liter it seemed almost obvious to go with twin T28 turbos. Now that we're down to 1.6 liters and 480 WHP the twin idea isn't so obvious. Dual T25s could be used, it's just a matter of boost onset threshold and how complete of a dyno queen this engine is going to be. Would spooling two T25s on this engine take much longer than a single GT30 or GT35, or maybe sooner? I've got no direct experience here except with a split pulse GT35 on a 2.5 liter engine. I've heard of a very similar thing done on a Dodge engine, but that was a 2.5 as well. So, am I smoking crack with this idea, or is it super bad-ass?

What about a ported N1, how good is for turbo?

Forget the twin turbos on the inline four, it is a good thought but one turbo will do the job better. There have been a few I have read about and are always let downs.

The Holset turbos might be a pretty good choice. I don't know if the one's from the Cummins motors will make that power or not. They do have "symmetrical twin flow turbine housings"

These ones will make the power
http://www.dentsport.com/2006/01/22/garrett-and-holset-turbos/

For a single turbo the Holset HX-35 seems to win out and can be had used for very cheap. The link above from jere has custom units with internal wastegates which would be nice to save money but pointless as the units cost so much new. Part of the dual turbo idea would be to save a ton of money on external wastegates and the turbo itself. Not to mention the exhaust plumbing is a lot easier with the internal wastegates and dual, side exit exhaust is easier. (I know I never mentioned this, but roll with it.)


Single turbo aye? Man that really sucks. Looks like the HX-35 is in order then but as a plus it is internally wastegated keeping costs way down and plumbing much simpler.

Next up would be injectors, and top feeds are cheap and all the rage so a top feed fuel rail is in order (custom or otherwise). 600-650cc flow-matched injectors should do the trick.

Custom intake manifold should rock a 75mm mustang throttle body (super cheap) with ford idle valve.

$100 eBay special intercooler, 3" eBay pipes and clamps/couplers...

Dual disc clutch seems like a good idea but way too costly. Solid 6 puck will have to do. Transmission could be stock from a S13 or S14.

Could save some money and rock a cheap-o engine management but I'd probably prefer to deal with AEM's Universal unit plus wideband.

Anything major I'm forgetting?

$1400 SR16VE long block
$600 Light/strong pistons with OEM rings (brand and material?)
$800 Light/strong rods with 19mm bearing (brand and material?)
$250 Cosworth headgasket
$300 Strong headstuds (brand?)
$300 Fuel rail
$250 650cc injectors
$100 Walbro 255 fuel pump

Subtotal: $4,000


$600 Intake manifold (DIY)
$600 Exhaust manifold (DIY)
$300 Holset HX-35 (used)
$300 Exhaust
$100 Intercooler
$100 Charge pipes

Subtotal: $2,000


$400 6 puck clutch kit
$250 RWD transmission

Subtotal: $650

$2,300 AEM Universal EMS
$280 Innovate Wideband controller

Subtotal: $2,580


Total: $9,230

shame on you ben lol, spending 9k on a engine and then cheap out on a ems, you know AEM is calling your name

That's why I said AEM instead of MegaSquirt or VEMS or similar. =]
Although when/if FreeEMS gets off the ground it will be a force to reckon with and would love to get my hands on it.

Why? You only need the head for a RWD application.



I would use a grommet style HG, i.e. A'pexi.



^^ These won't support your HP levels.

Your goal based on other cars I've seen, one just this weekend, is very reliastic, look forward to the progress.

If just the head can be had (don't know the current state of VE importing practices) then I believe that would work as the only thing I'm interested in is the head/valve train. Speaking of, I forgot to add valve springs and an N1 cam to the list... I assume oil pump flow between DET and VE is the same or not a deal breaker...
A DET bottom end at least would need to be sourced. Would much money be saved really?


Point taken. Didn't know there was such a difference between the two. I'll add it to the list.


You know what happened with the injectors? I got stuck in 6 cylinder world (I moonlight as a turbo BMW enthusiast). Damn it all. I'll fix the injector size too. From what I've heard the Walbro 255 should be fine up to 500 WHP or even higher. I've had one doing 414 WHP on E85. Either way, a Bosche 044 could be in order...

Thanks for the encouragement. I'd like to say again that I don't plan on making this leap until I at least finish my first. I'm sort of trying to find out how much I'll have to set aside for this project. =]

$1400 SR16VE long block
$600 Light/strong pistons (brand and material?) with OEM rings
$800 Light/strong rods (brand and material?) with OEM GTi-R 19mm bearing
$400 Stiff valve springs (brand?) to rev to over 9,000!
$500 A'pexi headgasket
$300 Strong headstuds (brand?)
$300 Fuel rail
$350 1,000cc injectors
$350 Bosch 044 fuel pump

Subtotal: $5,000


$600 Intake manifold (DIY)
$600 Exhaust manifold (DIY)
$300 Holset HX-35 (used)
$300 Exhaust
$100 Intercooler
$100 Charge pipes

Subtotal: $2,000


$400 6 puck clutch kit
$250 RWD transmission

Subtotal: $650


$2,300 AEM Universal EMS
$280 Innovate Wideband controller

Subtotal: $2,580


Total: $10,230