Sundance 6g72 "3.0 turbo build thread"(N/A DYNO SHEET pics inside)

[Ondonti]

I wouldn't, I tried to set mine conservative guess wise with my cam swap and it was 20+

Pretty sure you swapped the front and rear rocker assemblies and then got it correct on the last install.

This rebuild on the head I just did is the first time I ever took the time to actually pump up the lifters after cleaning them. I actually pumped them up all the way and then removed a little so they would not hold the valves open from being overpumped.

[Sundance 6g72]

It would have been impossible to swap front and rear because i did them one at a time

[RoadWarrior222]

drove the car. had some nasty lifter tick (scary lifter tick) until i gave it some hell.. then it seemed to be okay.. LOL probably the wrong way to go about that.

Not really, they don't fill much until you take it over 2000 rpm, so conservative city driving would have you ticking all day...

Recommended method though is to idle it up to warm, then cycle it up to just over 2000 a few times, holding it there for a few seconds.

[Sundance 6g72]

right. well either way it seems fine now. should have a timing light later today and get everything set. dont think ill drive it until my new plugs come in. screwed up and ordered 7s instead of 8s. my current ngk plugs are 5s so im not that worried anymore.

wish i wasnt turbocharged too. turbo screws with the power band way to much. i miss being able to change timing and actually feel the car to pull 300rpms sooner/later depending on what i did. cant really comment on the cams.. maybe the ve table wont start to dip as soon in the rpm range? NA would be easy to test this because i sit at 98kpa all the way to redline vs. boost with a junkwastegate.

[Sundance 6g72]

update

after cam swap (front cam seal and oring are NEW now) i seem to not be leaking oil

i had an interview last week and when i backed into my spot, their was an oil trail in the rain leading to my car. Its raining today and NO oil trail in my driveway from last night (hit 9.5psi a few times) and no oil trails today (not as much boost, maybe 3psi)

not driving again till its timing is synced and the new plugs go in.

and is it me, or do the mitsu cams make the car alot more rev happy? ign timing is either to much or to little ( i think its to little) but it seems to like to rev alot better. the cams are spot on this time, i think :P

videos are from cell phone. sound is not that great but im really in love with the sound of my exhaust. turbo, 2.5inch custom downpipe then 3inch all the way back with 1 magnaflow straight muffler right where the cat would have been sitting. sounds nice but its still loud.


edit: videos in a min.

[Sundance 6g72]

[Sundance 6g72]

gr7 plugs installed. should have gone with 8s but the ones i was running were 5s... so if i was fine before, two stages colder should work fine.

car fired right up, maybe better than before.. reved it a bit and it still sounded nice. just need to synch the timing then i can go hunt rice.

i was looking on a friends facebook. i was going to race his subi and their was some talk of me by another subi owner on this kids wall. "is joe the guy who built that bad --- duster?" LOL i guess my car is bad ---. cant wait for a dry day to see how these cams react with my wastegate shut instead of being held open.


oo and someone tell me why i havnt been ordering from rockauto before this.. ordered my and my dads plugs on sunday night.. get them midday Wednesday.. no fancy shipping just usps priority. love it. even got a nice magnet from them

[Ondonti]

I hacked off the top front of the passenger motor mount arm on my Spirit. That solved my clearance issue with 2.5" piping on that car.

[Sundance 6g72]

im about to do that too. i have an idea for a really low profile mount. bobby made one similar to what i want to do.

[RoadWarrior222]

I'm sure one could redesign the motor mount and lose like 200lb

[Sundance 6g72]

surprisingly the intake pipe has not ever blown off before the throttle body. it puffs up nicely though when i rev it a bunch.

made a little slideshow video while being bored. everyone is at work and i have nothing to do in the 2 hours before i go to work.

https://www.youtube.com/user/firefoxx04?feature=mhee

[Sundance 6g72]

road warrior.. i posted back in my for sale thread

[Sundance 6g72]

ran a modded wrx and a boosted 4.6 mustang gt. it was interesting to say the least...

before i get into it, ill say this. my timing was not set right. i got the timing light out and i couldnt find the timing bracket (one that says where the timing is at....) where the hell did i put it? did i unbolt it? LOL o well. i put the trigger angle back to where i used to have it and put the dizzy at the mark that i scratched onto it. car was not as fast as it used to be... but i wont complain until i know my intake pipes are all solid and not leaking, along with making sure the timing is spot on!!. but again, it felt slower than it did with the rear head retarded a full tooth and the front head on time.

so the wrx lines up with me at 45ish and im in third. we take off and i lag hardcore.. finally start to catch him when im redline. jump into 4th hard and keep the boost up and i continue to catch him. i eventually get past him but i consider it a loss.. i had to go way to fast to pass him. he said we did 130... i know i hit the limiter in 4th (6500rpms)

here is a video they took.. you see how hes way ahaid by a car or two and then i start to creep past. I need to fix the ghetto intercooler pipe before the throttle body and get the timing right!!! i know my car is faster than that. needless to say, it was fun.

video starts late


i had run the wrx 30min earlier but my shifter bushing fell out of place on a shift into 4th so he walked way while i idled down the highway. fixed the bushing and ran with his mustang friend who had stayed with me. they said it was stock but it wasnt... boost and all. i kept until he hit full boost and i heard his external dump open up and he was gone. we went again from 3rd and i kept a little better but he was still pulling. i think i would have had him if i had things right. Proper timing, intake, and REAR manifold. what a pos setup my rear mani is right now. Racing fast cars makes me want to make things right!

those guys got a kick out of my car and really liked the idea of it. cant wait to make it perform correctly.

[Sundance 6g72]

i like the new cams, didnt feel like i lost more power than i had even though i brought 4th all the way to 6300rpms. i was catching the wrx the whole time i was in 4th and i figured that if i didnt feel a power loss that i still had rpms to go but i was wrong and had to jump into 5th.

[Sundance 6g72]

so i broke and bought my car a present. I had to get a new FMIC kit. i ordered from the same place i did my last one. CX racing on ebay. the last set was surprisingly nice. I went with 3inch again so it would work with my old pipes and couplers. The new intercooler will be installed higher. Only reason the old one is trashed (not really trashed, bent is the better word.. i dont think it leaks) is because i found out that my car is NOT a rally cross car. Surprising i know, but its true. TD cars in stock form do not perform well in rallyX.

new IC should be the same as my current one. 31inches wide, 12inches tall and 3.5ish wide.

I also am ordering a 3inch inlet, x2 2.5inch outlet muffler. made out of t304 SS and looks just like the magnaflows.. just dirt cheep. we will see how it works with my current magnaflow that is installed in the stock Cat location. The cops will like seeing a muffler in the back as well..

also need to get an an alignment once all of my stuff is installed. i dont like the idea of the shop driving my car... o wells, not like they would be able to treat it worse than i do half the time.

[Ondonti]

shops driving custom turbo vehicles = scary.

[Sundance 6g72]

last time i brought my car to get tires rotated, my turbo was sitting in the back seat and the kid who shittily drives my car into the stall comes out of my car yelling to his work buddies.. they all come over and he pulls my turbo out and shows them all. LOL

but i dont like people touching my stuff. only reason i left it in there was because i was watching this all happen and not leaving for the 40min they said it would take.. pshhh

i might ask if i can pull it in and out.

[Ondonti]

I like to be able to sit there until something is done. I think I left my Spirit for the downpipe. I also let someone drive my Duster on 5 pounds at an alignment shop but it was an old guy who owned the shop. I actually told him to get on it cause I was bothered by its skitterishness which just ended up being the undersized rear tires.

If you are driving something with an aluminum flywheel and pucked clutch, its super fun to see how many times they stall your car.

[Sundance 6g72]

Who fabbed your downpipe?

[Sundance 6g72]

this is my revised spark and target afr table.

for spark timing, i dropped the advance to 10 degrees and ill increase it if needed. im hoping that ill need to adjust the idle screw on my throttle body. 30kpa at 500rpms has much more advance to help things out if the rpms drop. there is a cool table i can turn on called "idle advance" that lets me run a select amount of timing at idle. this is cool because if the TPS is at 0% and rpms are under lets say, 1300rpms, megasquirt will know im idling and switch to the idle spark table. so i would have a spark table for idle, and a spark table for when the car is moving. pretty cool. to bad my tps is wacked out right now.. id fix it but the only useful thing at the time was accell enrichment, that runs off the map sensor now, and quite well.

i dropped timing all over, starting in out of boost areas. I know i had been riding on the edge when cruising with timing at 36*.. at 37 i would get a miss if i went to lean. so dropping the timing a few degrees and AFR of 15.5 should get me a nice steady cruise. The solution before was to either drop a degree or run richer... ill settle for this and see how it works out.

the advance before the turbo hits full boost is much lower than before. evo guys run even lower.. like 10 degrees and as low as 6. i guess this gets the turbo going. ive ran about 36 degrees at full boost i think. Once full boost hits, timing is advanced but not as much as before. ill see how this table works out.. i want to get the turbo going quicker but maybe thats just due to my setup with the 3inch piping that needs to also fill up with pressure. Fun tuning without a dyno :bang head

the biggest thing for me with my new table is the 100kpa section (for Michigan, usually atmospheric pressure is around 14.6psi or close to 100kpa)

due to megasquirt having the map sensor mounted on board, i have to run a line to the cabin. if this line comes off during full boost.. i wouldnt want to be running the 45-57 degrees that i used to run when N/A because if the. I figure ill never be at 100kpa at 3000rpms or higher, so i set timing lower in this area. In other words.. at full boost, if this line comes off, megasquirt will think im at 100kpa vs. 160-170kpa and my timing would have normally jumped to 40+ degrees and i would go BANG due to fuel being pulled and timing skyrocketing.



the air fuel table is changed up a bit too. I like to cruise in the 15.5afr give or take a little bit. Ill have it idling around 14.5. Stock it liked to idle at 16-17afr when fully warmed up. I can do this with megasquirt and it idles nice.. but 14.5 is what everyone else likes to ill give it a shot. At highway speeds, tipping the throttle in gets me to 75kpa easily and close to 90 if i really need to. i might change 80-90kpa to 14.5 as well. Once boost starts going it tapers from 12.9 to 12.2ish and when full boost should be close to 12:1 afr. anything higher will start going to the high 11s. Ive hit 13:1 afr at like 5-7psi so im not worried about this setup. maybe it will make more power with the added fuel. its hard to get a straight answer from tuners.. they run 11.5afr to be safe and say that N/A cars make most power in the 12.8-13.1 area.. a turbo car might make more power at 13 but noone does that.

my current spark and afr setup likes to shoot flames when im up in the revs if i let off the throttle.. i hope i retain that setup. its kind of cool when its dark out and your mirrors light up a couple times.