GsiTurbo 2.0L 16V Turbo buildup ***DYNORUN 236WHP 255WTQ***

[GsiTurbo]

Upon my internet research, and talking to two 'independent' tuning shops, they are averall good. Yes, it had major issues at the beginning such as splitting compressor housing, but this has been since apparently corrected. Also, some people did not install oil feed restrictors (ball bearing turbos require much less oil flow than conventional bearing type cartridge). Eventaually, those turbos were 'blowing' oil.

[kinkyllama]

After seeing my friend's turbonetics turbo, I decided mine looks rather uninteresting..

What did you use to do this? Looks nice!

[decyphex]

yeah, what did you use to get it so nice and shiny? and what did you use to get everything on the engine so clean?

[GsiTurbo]

dis you had a problem with the fitme in the fuel rail with the OEM O rings ? where did u get them, what size ?
oem in the DSM injectors get too big and doenst fit in the fuel rail

Sorry man, somehow I missed this.

It did not have problems to insert the injectors. Yes, it was a snug fit, but it did not feel as 'wrong size'. Having said that, I did apply some assembly lube onto O-rings, which for sure helped a bit. I am using Accell 500cc injectors.

As far as polishing the compressor housing, I did the following:

Compressor housing must be removed from the turbo, or damage may occur

- lettering, markings and large steps were removed using large file
- hard to get areas got smoothed as mush as possible by hand with 100 grid sandpaper
- 180 flapper wheel was used to smoothen the entire surface (I used 3 different sizes)
- Redid entire housing in 240 grid
- used polishing wheel like this, and attached it to the die grinder. Used with polishing compound



And today I sealed it with 3 layers of clear-coat to prevent oxidation. Looks really awesome

Tom

[ubuyau]

Pretty

http://www.daewootech.com/forum/viewtopic.php?t=7466 I like to polish too

In real life is it smooth enough having done only up to 240? I found it was still very scratchy and rough with such a coarse grade?

--Tim

[exist3nce]

That compressor housing looks sweet. My buddy who has a 480 whp Camry did the same thing to his GT40R housing and it looks even better in real life! Not sure if he used the same method, as I never asked.

[kinkyllama]

Motor front:

Just lookin through the thread again, I can't beleive how clean that motor is....looks so nice.

[decyphex]

Just lookin through the thread again, I can't beleive how clean that motor is....looks so nice.

ME EITHER!! Makes me want to get my T20 that clean. They just dirty themselves up after a while though..

[GsiTurbo]

So this saturday started just like any other ordinary day. Since some of the parts I was waiting for arrived (together with Chris' items), time have come to put them to use.

Got the flywheel installed, together with the ARP bolts. This is the lighter 'flat' style flywheel.


Clutch and pressure plate




At this point, it only made sense to install the gearbox...




The day before, Chris, Rage_rman and I towed the GSI over the friend's shop (THANK YOU GUYS!!!!), so in essence the plan for today was to install the motor.





And somewhat in place


Then 2 hours later, after running round and finding all the bolts, nuts and brackets




With test fitted radiator


Altough the install was done after 9 hours (including couple of trips to get supplies, parts and food), everything went very smoothly in essence. Not a glitch (crossing fingers). With car hoist, proper tools and good help, this is really easy. At the end, I was very happy.

Tommorow all the gearbox linkages are to be reconnected, clutch cable. One of the rear calipers is leaking slightly, therefore rebuild kit is to be installed.



TO BE CONTINUED....

Tom

[kinkyllama]

muwahhaa. I like the style of those wheels as well...they look light too!

[GsiTurbo]

The rims are Kosei K1 Racing. 5 years ago, they were insanely light, at 16.7 lbs per wheel. But this is still light. Unfortunately, this line is now discountined (just when I need another wheel).

[exist3nce]

nice looking work Tom.

[Efratech]

wooohooooo finally its in! looking clean mate!

[kinkyllama]

The rims are Kosei K1 Racing. 5 years ago, they were insanely light, at 16.7 lbs per wheel. But this is still light. Unfortunately, this line is now discountined (just when I need another wheel).

I thought thats what they were...they arn't discountined??? In your size you mean or something?

I'm looking at actually buy a set for the street as they are one of the few 16s in my width that are light and not expensive...but I'm probably going to paint them as they only come in white or grey.

[GsiTurbo]

Update for Feb 6th:

- fabricated two radiator brackets. They are using stock anti-vibration bushings. Placing rods were welded onto the radiator. There will be 3rd vibration bracket, but final exact mounting location of the rad will be determined tommorow.
- build new upper crossmember support brackets



I was worrying about the alternator... since I am using front mount, I cannot get the factory tensioner/Power steering. Basically, in the end, I converted it onto manual tension system.. The tensioner bracket is from Lemans 1.6. It required some heavy duty bending and twisting to alter the shape, but at the end it worked


In the OEM setup, the upper bracket of the alternator is bolted to the bracket on the left. It is now replaced with the tensioner slider.