My 2.5L hybrid

[DBB mini]

So it's been a very slow process in the making but I am still pursuing the hybrid neon 16V swap into my minivan. I have done all of the machine work to the head with a few add libs. Intake manifold was made from an old O2 bottle. Head has some machine work done for oil drainage & crankcase to head equalization. I own a GT2871R so for free :lol: I'm using it. Machining my own fuel rail. I plan on plumbing into the exhaust for PCV. I plan on running -AN lines everywhere. I plan on fabbing my own header. I plan on running a T3 .86AR housing on my turbo with an external WG. V-band downpipe with WG dumping into 3" area. Old setup ran a double stock-wide intercooler (2stockers welded together). New plans for a triple wide.

I can take some pics of what I have so far if any are interested. I need input on several things. 1) I'm using the GT2871R for now. It has the Large T04E style housing so compressor maps are represented by the GT3071R via turbobygarrett.com & the turbo calculator via this site thanks to Frank. I'm using the larger T3 exhaust hsg with a .86 AR. I hope to make around 400 hp for now. 2) I have a 52mm throttle body & haven't welded the flange on to my manifold yet so room for improvement there if warranted. 3) I'm undecided about injector size & I'm on a budget so I'm all about the cheap. (planing on a cal/dyno tuning via FWD since she's so close). 4) I'm sh*t canning the gas tank for a fuel cell with external pump & 3/8 fuel lines. 5) I'll be fabbing in an alum radiator from summit. 6) Trans is already built but I need a good converter with torrington bearings. 7) I can either build a triple wide stock IC or purchase one & I'm open to ideas. 8) I made my own adjustable timing gears & I think I'm running 2.0L cams but open to suggestion. Keep in mind I'm a machinist in a fab shop so machine/programming time & weld time is free for me.

Thanks in advance for your input & like I said I will post some pics ASAP & any input, good or bad is appreciated so bring it.

Thanks again,:thumb:
Coy Johnson

[t3rse]

1: turbo should work
2: 52mm will make your desired power, but I'd go bigger (I'm setting things up for a 75mm if this gives you an idea of my mentality)
3: DSM 550 ccs are very cheap and will work...barely...at 90% DC (similar to +40s). This will depend on computer as well: SRT or late model is high impedance, old school is low impedance, such as dsm or stocker. I wouldn't cheap out and take the risk in this department, but I would stay away from RC engineering.
4: screw the cell, check this out: http://www.sdsefi.com/techsurge.htm ...use a secondary high output pump and a surge tank and you'll be fine...doing the math at 1000hp a 2 liter tank with an adequate pump will empty around half a minute with a stock pump? (190lph), and I seriously doubt you will need 30 seconds of continuous WOT, much less make 1k hp.

I have nothing else for you.

I'd like to see pics....

[turbovanman²]

I would go 58mm at least, but it does require you to weld on a auto throttle cam.

I can't give you any other advice, you seem to have it covered.

TC, TU has them or I am sure others will pipe in on where to get one.

:needpics1:

[DBB mini]

Head end work. T stat is on the end now. Machined a pocket on the head. On the left is a port that equalizes pressure from the crankcase to the head. The 2 large NPT holes in the end are for oil drainage back to the pan. I tapped the lowest point on the head so most of the oil will drain. Right side elbow is oil supply.
http://i57.photobucket.com/albums/g222/DBBmini/hybrid005.jpg
Here she is with the Tstat neck. Couple of NPT holes on it for guages, sensors, whatever.
http://i57.photobucket.com/albums/g222/DBBmini/hybrid004.jpg
Tstat hsg adaptor
http://i57.photobucket.com/albums/g222/DBBmini/hybrid008.jpg
Heres the intake. 4.375 OD, 3.937 ID modified oxygen bottle. Stock sawed off cast intake runners & flange. Stratus I think. O2 bottle had a nice slow radius in the bottom so I cut it off (bottle was too long), machined it for perfect alignment & had it welded back on. I used a nice dual head boring bar to radius the runners to match the OD of the tube, cut 1.8 dia holes in the tube, had the runners welded to the OD of the tube, then radiused the runners/ID of the tube from the inside.
http://i57.photobucket.com/albums/g222/DBBmini/hybrid001.jpg
Different angle.
http://i57.photobucket.com/albums/g222/DBBmini/hybrid002.jpg
Heres the gears. I made the inner, used 2 stock 2.5L gears & machined them to fit the inner. Adjustable in 2dg increments.
http://i57.photobucket.com/albums/g222/DBBmini/hybrid007.jpg
Heres a shot of the old 2 core IC I ran last. I have another core so I'm thinkin bout making it triple wide.
http://i57.photobucket.com/albums/g222/DBBmini/hybrid003.jpg
Thanks guys for your input.

[turbovanman²]

Wow, nice machining, it would be so cool to be able to do that, I have to beg/bribe my machinist buddy for stuff.

[t3rse]

purty! :thumb:

the two most important relationships you can ever make: 1) local law enforcement 2) good machinist, or else someone who has adequate equipment

[2.2turboscotty]

VERY NICE! i am starting on my son's hybrid build and you have helped me with your pics. i am going to have to build an intake close to yours, it also helped to see your therm. housing pics.
very nice work

[DBB mini]

Thanks guys. I wanted to ditch the gas tank so I don't take a chance on debris clogging my filter/pump sock. I removed it & cleaned it out but there's still some trash in it. Seems like I just can't get all the trash out of the 20yr old tank. Are 52pph injectors the most flowing low impedance I can get? I was thinking I'd need 65pph or better? Or the equivelant cc?

Before I make a flange& have it welded on the intake is there a good 60mm or close stock style throttle body I can use? Mustang? Camaro? Should I just bore my throttle body out to 58mm & make a new butterfly?

Thanks again.

Coy

[turbovanman²]

Thanks guys. I wanted to ditch the gas tank so I don't take a chance on debris clogging my filter/pump sock. I removed it & cleaned it out but there's still some trash in it. Seems like I just can't get all the trash out of the 20yr old tank. Are 52pph injectors the most flowing low impedance I can get? I was thinking I'd need 65pph or better? Or the equivelant cc?

Before I make a flange& have it welded on the intake is there a good 60mm or close stock style throttle body I can use? Mustang? Camaro? Should I just bore my throttle body out to 58mm & make a new butterfly?

Thanks again.

Coy

Some guys run the Mustang t/b but then you have to figure out the idling etc, but if using standalone, your fine.

You can get a 58mm TB that bolts on the stock flange, you just need to grind out the lip just before the blade, its like a ski ramp?? idiots, lol!


http://i12.photobucket.com/albums/a228/turbovanman/tb2.jpg


http://i12.photobucket.com/albums/a228/turbovanman/tb3.jpg

[DBB mini]

SWEET! Thanks Simon, what vehicle did the 58mm come off?

[turbovanman²]

SWEET! Thanks Simon, what vehicle did the 58mm come off?

Some 3.8L Minivans, theres no real rhyme or reason to find out what years, but it seems long wheel base or tow package mini's got them. Other than that, hit the yards with a tape measure, :thumb:

[DBB mini]

Thanks Simon I'll take my calipeters.

[cordes]

IIRC I have seen low impedance injectors in sizes all the way up to 160PPH. I know they have 72s, 92s, 120s...

[DBB mini]

IIRC I have seen low impedance injectors in sizes all the way up to 160PPH. I know they have 72s, 92s, 120s...

Where would I get some low 72's?

[cordes]

Where would I get some low 72's?

This is the first place that came to mind.

http://www.fwdperformance.com/store/Product.asp?IDCatalog=7&ProductID=543

I have seen them for as cheap as $65 elsewhere, but I have actually had dealings with FWD. If you call they might be able to get you larger ones for about the same price. I have seen alky compatible injectors in the 95-120PPH neighborhood for about $80 each.

[DBB mini]

Thanks, I'll probly have the cal done there as well, so one stop shopping.