Turbo D16 Sedan - how to roll with AC
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From: b00sting my D16s, SoWis, USA
I tend to have more ideas than time/money, but due to a *****-to-the-wall effort the last 4 weeks, I'm basicly done with this idea. Its all within budget so far - $5k for shell/materials/tools. ALL work done by me, as I didn't trust anyone else due to such tight fits & such. <U>Feels insane above 10psi.</U> Roaches the tires all the way to redline in 1st and 2nd - with a long-*** DX/LX tranny. (granted they're just steelies
)

The biggest problem is the car has no easy route from the turbo to the FMIC. I just cut the metal next to the AC canister thing (where the washer bottle was), and had a perfect route. I used an HF manifold with an angled adapter to swing the turbo's internal wastegate from the AC compressor. Regardless of which manifold you use, it has to be custom fitted, as the enginebay is tighter than a virgin. AC lines need to be bent quite a bit as I did (or custom bent). Heat sleeves or a ceramic coating has to be used on the downpipe/turbo/manifold to prevent melting/heating the AC lines. You may also have to move the condenser back ~1" on the driver's side if you have a thick FMIC (assuming you dont RAPE the bumper). Horns also have to be relocated. The other obvious thing to do is the ghetto-lean on a dualcore EG radiator. Behind that I fit a K&N with 3" piping to the turbo.

The most fun part of the project was the full 3" downpipe & exhaust. The piecuts didn't take as long as the 'hump' over the rear axle. Not as easy to do when you have a 22mm rear sway in the way.
)
The biggest problem is the car has no easy route from the turbo to the FMIC. I just cut the metal next to the AC canister thing (where the washer bottle was), and had a perfect route. I used an HF manifold with an angled adapter to swing the turbo's internal wastegate from the AC compressor. Regardless of which manifold you use, it has to be custom fitted, as the enginebay is tighter than a virgin. AC lines need to be bent quite a bit as I did (or custom bent). Heat sleeves or a ceramic coating has to be used on the downpipe/turbo/manifold to prevent melting/heating the AC lines. You may also have to move the condenser back ~1" on the driver's side if you have a thick FMIC (assuming you dont RAPE the bumper). Horns also have to be relocated. The other obvious thing to do is the ghetto-lean on a dualcore EG radiator. Behind that I fit a K&N with 3" piping to the turbo.

The most fun part of the project was the full 3" downpipe & exhaust. The piecuts didn't take as long as the 'hump' over the rear axle. Not as easy to do when you have a 22mm rear sway in the way.
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Joined: Jan 2005
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From: b00sting my D16s, SoWis, USA
I never measured the oil line, it was the kit stealthmode sent me. I hate to confess it, but... my braided return line - drops down farther than the pan fitting. But with a hand-made 0.060" restrictor, I only get a hint of oil blowby when I rev it out of gear (love the BOV sound). Turbo wasn't perfect before hand, but it doesn't smoke at all.
Now that it's all done, I may be getting a full size rad back in again. I wasn't sure it would fit before I got everything in place. But as it is, I've boosted up & down my 'tuning' road, and its never moved the needle. It looks goofy in the pics, but in person, it fits just right.
I would like to get different AC lines made & have a connection with a guy who does that, but I'm too cheap atm, and still have some things to do. I'm currently nursing slight CO poisoning, so it seems
For the record, the last car I tuned - 00 Si, stock b16a2, ssauto 57trim kit, stock exhaust, 6psi - felt a bit slower than my sedan when I was pushing 9psi. I can't wait to get better gearing.
Now that it's all done, I may be getting a full size rad back in again. I wasn't sure it would fit before I got everything in place. But as it is, I've boosted up & down my 'tuning' road, and its never moved the needle. It looks goofy in the pics, but in person, it fits just right.
I would like to get different AC lines made & have a connection with a guy who does that, but I'm too cheap atm, and still have some things to do. I'm currently nursing slight CO poisoning, so it seems
For the record, the last car I tuned - 00 Si, stock b16a2, ssauto 57trim kit, stock exhaust, 6psi - felt a bit slower than my sedan when I was pushing 9psi. I can't wait to get better gearing.
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From: b00sting my D16s, SoWis, USA
lol, its really not that bad. I just didn't feel like wasting time doing a full tuck, rather making it work. I also plan on finding a *cleeean* EX/LX shell to xfer all the stuff over to, so it has to be easily to make stock again.
Really its just all the stock LX crap. It still has the PS res (made it the 'recirculated PS' breather tank), cruise cables, longass throttle/tranny cables, and enginebay mounted relay wires. If I posted the original picture when it was 100% stock dpfi, you'd understand. It looked like someone **** plastic and rubber into the engine bay, like these newer cars.
All I care about is that I can freeze my feet while burning rubber. lol
Really its just all the stock LX crap. It still has the PS res (made it the 'recirculated PS' breather tank), cruise cables, longass throttle/tranny cables, and enginebay mounted relay wires. If I posted the original picture when it was 100% stock dpfi, you'd understand. It looked like someone **** plastic and rubber into the engine bay, like these newer cars.
All I care about is that I can freeze my feet while burning rubber. lol
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From: b00sting my D16s, SoWis, USA
They came that way, sprayed silver. Go ahead and do it, but remember to prep them right (sanding), and only put on very light coats. Less is more.
Right on Hi, I missed this as I don’t stop by the ef room that much. That **** is bad *** I love the “I don’t trust anyone to do the work, expletive you, I’ll do it myself” attitude! Those that can, do! It looks well thought out and executed! Great job!
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