Posted by BrApple, May 29 2008, 08:56 PM
well tonight I was finally able to install the intake tube and air filter. I had to trim alittle bit more from the fender area to fit the tube but all worked out. After that I was going to mount up the power steering cooler but I found that the bolts I bought which I thought where the same where not. So I just left it how I had it. After that I drove around the storage area. There was no irratic idle as I had before. Some of of the drive way area had just been re-tared. I easily left 10 to 15 foot strips in a few places without trying. After that I went for a road test. The car performed really well. I just did the loop around the block a few times. The car pulled nicely and was well manored. I put the bumper on for a test fit and found the filter contacts the fog lamp. So I think i will cut the intake tube about an inch shorter to make it clear. It also looks like it maybe to far out to install the bumper so I might have to modify the fender openning some more to get the filter to tuck in more. Oh well just more to figure out tomorrow. But at least the kit is installed completely and works 
Posted by BrApple, May 28 2008, 09:08 PM
well it took from 5 to about 8~8:30 but the wastegate exhaust leak has been corrected. To get the wastegate out I had to dissconnect the exhaust and remove the downpipe with the wastegate attached. Well to my frustration it wouldn't go back together that way. So back out it came and I also had to unbolt the turbo to get everything to line up. Again the allen wrenches with the ball end ftw, I was able to get to all four wastegate bolts with one. Now after hitting boost I can really hear the blow off valve. Down side was I still wasn't able to get the intake and airfilter installed. I did however get a new coupler to replace the one I cut to short. So hopefully tomorrow I will be able to get that installed. I also have to remount the power steering cooler to the bottom of the intercooler. After that I will be able to get the bumper re-installed and road test everything.
Posted by BrApple, May 27 2008, 09:09 PM
well I kinda broke it already ....
that exhaust leak is at the wastegate. I thought I had it tightened down enough but I was wrong. That first time I really got on it the gasket on the up-pipe side blew out. I tightened then down more today but what was done was done. I was over excited to drive it. So my hope is that I can just pull the two bolts and slide the old gasket out and slide a new one in. otherwise I have to pull everything back out. At least I can get to three of the four bolts fairly easily. So I think I can take the two bolts on the blown side out and then the third that I can get to and rotate the wastegate out of the way alittle.
have to see. the only down side is it is leaking metered air so its going alittle lean at idle. however under boost the A/F is good. I think that I will also take the chance to re-run the oil drain. right now it runs behind the header to the tap in the block. well its very close to the header, however it does have a 2k degree thermal sleeve over it to protect it from the header. I am thinking about putting the nipple right into the block and then running the oil drain in front of the header to the block. This way its away from the heat.
Posted by BrApple, May 26 2008, 08:53 PM
so yet again another long day getting the turbo installed and up and running.
The morning started off with getting all of the hot side piping and turbo installed. By early afternoon that was completed. I then went about getting all of the charge pipes installed. Alot of the couplers needed to be cut down to make everything line up correctly. All in all that wasn't that bad to do. I did however cut the one to the inlet of the turbo to short. This brings the maf enterence up to high so I wasn't able to install the intake pipe and air filter. On start up the car idles very nicely. After pulling it tends to want to die but alittle gas helps that. With the 3 psi spring the boost comes right up to 3psi and sits there, meaning that everything is working as it should. the bov isn't that loud but in the storage unit I can only go fast. I think it isn't that loud because of the low boost. The first time I was able to shift to second on the power an exhaust leak developed. With Rogers help we quickly determined its the first exhaust joint after the down pipe. So tomorrow I will have to go through all of the exhaust joints and make sure everything is tight. I will also be ordering a new coupler tomorrow so that I can install the intake correctly.
The boost comes on slightly before the secondaries open I believe. The power is seemless. Rolling into the pedal just makes power and the turbo spins up really fast. The exhaust leak make it sound so bad ass, but that will get fixed.
Pic from around noon time where I had all the hot side piping installed and tightened down.
after running the car the first time and hitting boost
Posted by BrApple, May 25 2008, 03:29 PM
I feel like I got my ass kicked today ...
I started off with a new tune from Joey. Everything was running right so on to the turbo install.
I was loaned a hole saw from some other guy at my storage unit, he was working on his car and snapped the allen wrench off in his coil over adjustment. Luckly the magnet I had was small enough to get the peice out.
So I started in on cutting the whole for the intake pipe. It was pretty slow going and the batteries died for my drill pretty fast. So I run over to Home Depot and pick up a corded drill. I get back to it and the hole saw isn't working to well ... go figure it wasn't for metal. So I run over to Sears and got the one I needed for metal and was done within a few minutes. After all of that I got all of the hot side piping installed and was playing around with installing the turbo. Well it was when I tried installing that intake pipe I drilled the hole for that I realized that it had to go in fist before the down pipe. So back out everything came. I then went about cutting the slits and bending the metal back to get the pipe to sit furthur into the frame. I also got the whole slightly off center so I am working on straightening that out also. I then went to install the oil line and hit two snags there. First I cant easily get the plug out of the head and I didn't have a stubby wrench to get the cap off the oil drain. So off to sears again to get what I needed and here I am now, taking a break.
I might go back and do more tonight but I have to see. Thinking about taking it easy as I have been working at this since 9 am this morning.
more later
Posted by BrApple, May 21 2008, 06:57 PM
getting closer 
I was able to upgrade the fuel system today and tune the car. Everything was straight forward. The injectors and spark plugs where easy to swap. I was able to get it all done since I figured out an intake last night so that I can drive the car. I took one of the intake pipes that actually comes after the MAF and used that to install the 80mm maf and I picked up a cheap APC air filter to use for a few days. The tune was very easy to upload to the PCM and the car did fire right up. For the forst few minutes it didn't want to idle, ie the idle was very low but keeping it reved up for a little took care of that and after alittle time it came right down to the correct idle. I ended up about 5 minutes short of a down pour to be able to actually drive the car and see how it is. The tune I used is my turbo tune. But since my understanding is its set up to add fuel based on the amount of metered air it will run fine either as N/A or boosted.
Posted by BrApple, May 20 2008, 06:31 AM
well now that Spring Zing is done and over I can get back to my turbo project. First up will be the fuel injectors and spark plugs. I have the 42# injectors and the NGK TR6 spark plugs to install. I will then either just make sure the car runs without any fuel leaks or I will try to get the 80mm maf installed so that I can tune the car and make sure it runs. I hope to be able to finish this tonight.
I am giving myself a two week deadline to get this project complete. I would like to take the car to the All Ford Nationals in Carlisle, PA and have it complete and running with the turbo.
Slight change in plans now. I really want to dyno the 3L as it is now before installing the turbo. So if I can make that happen before the weekend I will. Problem is Bristol Dyno where I normally go has closed but its in the same building/shop as Victor Research so I am trying to find out if they can dyno the car on the same dyno as I have been going to.
Some side notes about SZ. The weather was great yet again, lucked out there. The SVT with a KKM, glasspack and 2.5 inch piping from the rear y back to magnaflow mufflers put down 172/154 iirc. Not bad numbers for a pretty much stock SVT with 46k. The SVT also almost won the Show and Shine. It tied for second with 13 votes and lost to the 1st place car by one vote.
Tonight I was able to play around with some of the turbo kit piping that I have and my new MAF. I have found a way to install the new 80mm maf so that I can install my injectors and tune. I was able to take one of the intake pipes that happens to be a 90 bend and run that to the stock accordian tube. The stock tube is alittle large but the pipe goes way in and it clamps down well. This allows me to then attach the maf as this is the same tube that comes after the maf in the setup. Only down side at the moment is I do not have an air filter that has a 4" openning. I think that a friend of mine does so this will allow me to drive the car to make sure the tune and fuel system are working correctly. Still looking to see if I can dyno.
on Done