Project MX-5: Fitting My Epic Turbocharger

hello and welcome to the Autosport international show at the NEC in Birmingham the aim of this weekend is to fit Phil with the turbocharger so I'm going to be looking at about what 700 horsepower Nick yeah try about 250 ok maybe closer to 250 you may remember Nick here he fixed Phil you save Phil from rusty heaven hell no that's definitely hell and I've also got Gareth here and Mark who also works for skuzzle so we're gonna be fitting a turbo to Phil and it's gonna be glorious here we have the turbo for Phil from turbo dynamics I take it we just whack it in there does it go like that maybe up I mean what how do you turbo a car well and how involved is it to be fair it's not too bad a job we've got to take the exhaust manifold off and fit a manifold with the turbo bolts do exactly and then a bit more exhaust and some more lines and water lines and plumbing all in so it's a simple job right oh yeah if you know what you're doing there you go have that I'm gonna go and we've got a lot of work to do I'm gonna go walk out it's done before the 8 I know Marc Marc starts by disconnecting the downpipe from the cats while I undo the bolts to the Jackson Racing cold air intake gareth meanwhile gets to work removing the old injectors so I've just come to join mark from scull wonder Neath Bill we're all jacked up and we're good right it's these no we're just gonna fall on our heads what are you doing the moment that's a quick job and you nearly done yes amazing I'm gonna leave you to it because I get claustrophobic bite at the moment i undoing the bolts for the exhaust manifold Nick what are you doing at the moment I'm taking the injectors out and with with little petrol everywhere oh but it's alright it's alright any opportunity you can if the injectors are out replace the o-rings and all the seals because you don't want them leaking on you we're at the show there's probably loads of them here for sale nick puts in the new RX 8 injectors while i wrestle with the exhaust manifold bolts so as you can see I've got a chest strap I'm just gonna be the cameraman so at the moment what's going on mr. Nick well because someone Blanca decided to wrap the manifold yes that was an eight-room to get the spanner in there we got it on so we will get it off I'm gonna I'm gonna persevere with this yeah as you can see we have meat wrap in the way of this and you can't actually get this spanner in there so I have an oil leak isn't that only because of the rocket ah the gasket if I replace that then yeah then we'll be good to go so when I come and see you for the tune-up I will come along with a rocker cover gasket and then we'll get it on with the gasket in under a minute under a minute under but that means undoing all of these look on and all of these in under under a minute emotional vocal fins gasket if you don't do it in under a minute then you did a rust repair on my e36 m3 I will give you one minute and a half one minute and a half yes one minute and a half in exchange we're not having to do that right yes if I can do it before we've already shaken on it you can't buy your steak by mistake okay that is deal I don't know like I'll buy you I'll buy you a cow would you like to have the moment yes yes I want to share in this pan at the moment and we and we have been reading the comments on YouTube so like all of you said we've unplugged it rather than unbolting it and we were involved it when it's on the floor yes yes high-five oh yeah let's take this out together this is our moment oh oh my god ah yes exhaust manifold is off what I have to throw it to do it again yeah throw it to me throw to me oh my god oh no oh we're done we're done we're done so I've got my new exhaust manifold for the turbo and this has been given to me by black cap fabrication so I think we should do a quick test fit and make sure that everything fits and then we've got to do a bit of filing and then job should be good and then we'll throw the turbo on and there's 700 horsepower done it's on there we go there's Phil's new exhaust manifold that's good welding I like it's pretty I then file down the bracket that's in the way of the new exhaust manifold while Nick removes the exhaust gas recirculation pipe before blanking it off success right so we're at a stage now where we need a few bits and pieces we need a hacksaw and we need a few other bits as well so I'm gonna forget everything because my short-term memory is completely shot because I'm really old now so why don't you just give me a shopping list of stuff okay right so I've got my list of things to go and get I think the best thing now would be to head out into the ether and go find some stuff Gareth you want to come along do you have any tools because I need to do some like foiling we know whether there's any axles yeah agent where we are it's my honor hey Ruby something is okay they're like like you can help we're actually you know where we can purchase would you be able to provide said things and then we give them back to you off which see this Wow this is amazing right so I've got my hacksaw we've got the bucket we need to drain the radiator and we need to hack this corner off what's this nipple that you've put in there well on the block originally there's there's just this it's a little bulb that yeah kind of doesn't really do anything so we're taking that outward and put that in the beam that fitting now if bummed into the block and go straight into a high-pressure oil wait so then we screw this on to that now uh yeah yeah and that goes into the top of the turbo to keep your turbo so Nikki so Mazda actually designed this engine to have a turbo bolted onto it otherwise why would they have put they actually locking bolt master all I could say to you is thank you very much because you're making our lives quite a lot easier okay sweet oil feed pipe it's not done up yes I will remind you right now it's my turn to get hack in yeah this is gonna take forever there's gonna take a long time I've not made a dent where we go really forward of hacking this and Plus this hacksaw blade is pretty much blood so we're going to try fatigue when this bracket over here with a pair of mulberries oh look at that it's looking tired already oh good work the bracket is off so we can now put on the gaskets and then the new turbo manifold before bolting it on so next I'm doing Paul yes right and then I detect top hoes there some old room hi when an openness a kiss next I remove the under tray drain the crappy old radiator and throw a tea bag on my windscreen so I've just been given a drill and I've been instructed to do some drilling so if you just give me the intercooler where was it just then and that was it no do we drill in the car oh the car good job yes now we need to fit the intercooler but to do that we need to get this piece of metal piping threaded pipe cut I've tried to do it with a with a really blunt hacksaw so that's not happening so I'm going to try and waft around with my chest mounted go probe and find someone who will thank you so much you're a lifesaver so what's gonna happen now Nick well I'm gonna stick me into the corner in we're supposed to be yes I'm gonna fit that you're gonna get the turbo yeah and a down pipe I think marks gonna fit about here it is elbows here I think marks gonna fit the downpipe yeah it's got in his hand yeah and then you're gonna fit the turbo with his assistant yes and I'm gonna fit that yes and then we've just got a plumbing fan in so there you go cool I'm just gonna throw this at the engine and hope for the best so the downpipe is in loosely you put on loosely now we're going to test fit the turbo so what just walk it on I do know what you mean so what does that mean that means you're gonna talking it right yeah I then twist this so that needs to be facing downwards yeah yeah but you've missed a bit oil feed has to be directly on the top aha so we're gonna have to clock both half than turbo so we can have two on dude outside and we'll rotate the core and then I'm doing this I don't rotate that now okay was that easy easy sweet easy as pie on a freshly rebuilt beautiful turbo from turbo dynamic on sale by dynamic alright let's take it off and clock it so how do you how do you clock this how do you everything around all it is is just on doing those knots and then we've got one there are a few components I've taken the ruler I make about hammers around right out of lying clamp yeah up from around the the exhaust housing yeah so that's what clamps a quarter to the exhaust side yeah and now we put the actuator out of the way so if we don't have to get that in a way yeah we couldn't be easier thing from that way of that but you're here I'm a green using me that gets rid of the actuator and in a minute we'll actually pull your brand-new turbo apart so now see how that spins around I do and let's turn in this whole section yeah and we know we want the oil feed at the top at the top and the turbo sits in the engine bay because of that flange there at that sort of angle yeah it was like that before yes it was yeah so now we just push that so it's at the top chops are good and and then we can put that Bank yes what I will do is take it to the car and just check that isn't exactly the right place that's a good idea if we take the sharp into this that we used to draw on your arm earlier we can mark the turbo in the exact position we want to put it and then that that is a really awesome table okay honest okay we don't see many like this they're normally old and rusty so that's where it's it yeah and we need that oil port at the top and to be as much of it so I'm walking like that yeah so if you put a line across there so now when we put that back up against the flange we've actually got the oil feed as the profiles directly at the top yeah and directly on the bottom is the oil drain yeah because the drain it's gravity that drops your head out of the turbo so now it can just drop down sweet it's just perfect what we've got to do now is get the angle of this right we can fit that any way we want it's just what's gonna work best for us so I'm looking down that hole thinking there's quite a bit of room there for a boost pipe yep so we should probably point it straight down yeah pop it on that way up if you could make a mark between that housing and no not that bit forward that would know that's forward between this house in here opening and the core below now we know where we're putting that yep yeah come on now that looks pretty good with the turbo now marked out we take it back to the bench to tighten everything up now the fun starts we put the shortest bolt in the leftmost part of the manifold before putting in the other longer bolts once in we tighten everything up and move on to the intercooler provided by mx-5 hearts and tuning company last five this feels right yeah this feels right all right basically you drop it down a bit right well that's right hang in there now so you can let go sweeps with the intercooler installed we whip out Phil's old grill to significantly increase air flow with a grill out Nick tasks me with an actuator modification job by taking I'm gonna be drilling there I need to hole there I'm on it yes boss would you be willing to drill through that and then we can get the actuator on my turbo you're a lifesaver right here yeah thank you very very much indeed is a problem with the actuator drills we add both the braided oil hose and the actuator to the top of the turbo what are we doing underneath fill we're gonna drill stuff under the car I have a feeling you're gonna be drilling for some yeah is this the exciting bit well it's the most people don't like living I will do it no I'm not gonna do this I'm not gonna do it so we're gonna drill it yep approximately there okay but everything is awkward I'm gonna worries when you're on that Demerol you get a move ah all right but then if you noticed well put some tape on yes yes that's the point if we go that far we've broken it okay because then we can't fit for him that we have is such a good shot that was that was perfect we've done good man there's no smooth in there we've done that well that's exactly what's supposed to happen key to successfully tapping a hole yes just keep it as square as you can yeah the whole time not like that see I had a little wobble right yeah I saw that that's not ideal metal coming out yes we are in yeah we have a fretted hole yes I'm gonna insert my finger into this hole that I've just tapped and feel around for swarf see there are some my finger basically we're gonna scoop out as much as we can which is exactly what I've just done yeah and that's it there's no more you can feel inside and we will meet to do the rest we're just gonna screw in the piece of metal yes you know we took metal out we're putting metal back in and what is this piece of metal well that's that that is your oil return from your turbo metal the fit and we're gonna use to put the pipe on to Joey should we get underneath and yeah go do some screwy yeah right okay we're gonna go screw on the car now Jimmy that's really nice and lobster look at it look at it oh yeah my field Unni just a flat just give it a nip just a little nip that now your oil can go in instead of coming out the intercooler from fast five has been fitted now I'm gonna fit the brand new radiator so brute force and ignorance yes here it is isn't that pretty as they one draws to a close our final task is to attach the existing fan to the shiny new radiator and fit them in place the show is now winding down we have fitted the turbo the intercooler the new radiator and our googly eyes as well I did that all by myself now we're gonna call it a day we're gonna shut up shop we're gonna go and have some steak and then tomorrow we're gonna be back at 8 a.m. I haven't told you yet but we're gonna be back at 8 a.m. sweet let's go home it is day two at the Autosport International show in the NEC in Birmingham and we are doing the live turbo build for Phil today we're going to be doing pipe work and stuff that's not quite as cool let's move on from that and get on with the build we've gone in a pilfering mission but we couldn't find any gasket materials so I've torn one of those Vistaprint packets apart which might do although it is quite shiny on this end so what we're gonna do is we're gonna get some oil this might work should work from Phil and dab it around there then hopefully this will transfer onto here and we have something nice to cut from it'll do I reckon it's alright we've made this we fudged this gasket and this is the the return for the oil coming out of the turbo so that fits on the bottom there with two m6 nuts and then we're going to use some piping a little bit later and join that part undo this that goes into the sump and that should complete the system so the oil comes in via this beautiful braided hose here goes swirly swirly turbo and then gets spat out and then goes into the sump where it's returned into the engine pretty sweet so I will now be fitting the pipe and then we have a complete complete it's okay right yep sweet can you give it a tug up yes what's happening next what is water like like I want to try skipping this is gonna end badly I'm getting out of the way bad back oh my god this is amazing left foot yes so in order to call the turbo now we need to plummet into the water system so what we've done here is this little pipe used to live somewhere like this which goes into the thermostat housing so what we did was we pulled that up and now we're attaching some more hose to it which will feed into the turbo and like the oil system for most luke in and then back into that part into the thermostat housing and that should Oboro falafels exactly put in the water line onto the fitting that we've got on the turbo that's water in and then we've got to get water out meanwhile what is Mark doing I'm extending your o2 sensor because it's too short yes it's too short to reach the if we've got like that having exhausted the water and the oil then it's just like the stuff going in and fangs squeeze and yeah sure boom so what was happening zooming zoom one of these pipes burst pipes these pipes urge so Ethan you want to you want to get involved you want to be a chief mechanic or do something you want to be a chief mechanic like me this pipe yes needs to go over that okay how are you gonna tackle this yeah maybe oh this is pretty though I don't know what it why don't you just apply some of that just I'm so there Oh oh yeah get it on that one oh oh we're putting the bottom radiator pipe on the bottom red pipe back on did the top wall Ethan so avidly did the top line you could even could you get the bottom of q8 sprays it's on the top of the engine yeah I won't need that no Ethan Ethan thinks you need it okay so he sees golang thing he's coming with me okay there's only bad city so then that's good evening I'll get hold on if you hammer something okay hey guys let's just do that say any more stuff you could hand to us even just hold on let me let me just help you then there you go yeah just like just go at it in go what's your face watch your face what's your plaything we need to adjust they go well you watch your face did it we did one more yeah well yeah cool right so being let's start with the ducting it's filled it's pretty sweet however this is a reducer pipe one of the only ones in the pack so that will go on to this outlet of the turbo and this will allow us all to use standard piping throughout the rest of the car thanks you're welcome - it should go on with a reducer pipe now on the turbo Gareth and I connect the rest of the boost pipes to fill i'mjust plumbing in the actuator what this does is it opens a waste gate on the turbo without a waste gate all of the exhaust gases would be passing through the turbine spool in the turbo and creating so much boost that the engine would just blow up straight away instantly it would be bad so what we've got is we've got an actuator that opens wastegate the wastegate allows the exhaust gases to bypass the turbine at the boost pressure that the actuator says that we want to have so this is probably about seven psi so when we get to seven psi this rods gonna move that flaps gonna open and we're going to stay at 7 psi all the time until he lifts off because he's scared it's a good time to run the vacuum line for the ECU because each use got what they call a map sensor a manifold air pressure and that's one of the main senses it uses for working out how much fuel to put in and what ignition targets are run so I've got it in my hand we might as well plumb that in somewhere the EC is going to live so I'm gonna crack on with that so all of the boost pipes are in and now we're just struggling with the last remaining Drupal Eclipse it's a bit of a faff getting it down here cuz there's a lot of other pipe working away but we have one to secure and tighten and then one more to put on and then the whole system is complete hello mark what have you been doing I've been removing your ECU apparently so we're gonna fit my old RCC you with this ECU so motorsport electronics has given me an M II two to one ECU that looks a little bit like so we've just got a few make which is turning on voltage as I've done off-camera perfect and ECU this is what's been limiting Phil for years and the driving talent and driving talent if I were in your workshop I would throw this against a wall no no no no really when I do that we need to keep the case and put the new ECU into the case of tank but we're going to take the case completely apart that I throw this on the floor now we've carefully removed okay you can smash it a bit it's really this is like the latest and greatest most awesome a piece of ECU engineering in the world we then put the new ECU into the old housing and screw it into place okay well before we can actually put this completely back together there's a couple of things we really need to do we've got some jumpers so we can move some jumpers around so that the board knows what car it's working with so the other two fairly important jumpers to do with the throttle position sensor we've got take this jumper there and we know that we use in on the 1.8 mx-5 we have a linear throttle position sensor and this jumper here allows the ECU to put out a 5 volt signal to that throttle position sensor so we just put that on because that's what we need for this this car and then the only other thing we've got left to do we've got the map sensor on the board we've got a vacuum line in the car that we've already run we need to get that inside onto this map sensor on the board and they've put the map sensor perfectly lined up with a screw on the back of the case which we don't need to use especially that one there so what we'll do we'll take that screw out and our vacuum line can run in through that hole and it will point it straight at that maximum sensor there with the turbo conversion nearing completion Nick had one last hunting mission for me I had to find an oil breather filter and an air filter Jake from Piper cross was very kindly donated this but we think that this is going to be too big because this is Japanese on a line belt notice no Indian so we're thinking maybe if we can use some of the piping stick it in there and just clamp it all together yeah might do the trick breather filter down time to locate an air filter you are literally our last hope thank you very very much yes yes we have this we've got it we're gonna need to we're gonna need to bastardize it a little bit but it's there we've literally spent the past hour a whole hour chasing round two holes baking borrowing and stealing and finally racing line gave us this one which is going to be a little bit too big but they very kindly donated it to project mx-5 we then got back and then mr. John marker said what about that one in the corner that one being this so Nick Bailey of skuzzle actually had this the whole time but he told me to go and find one to go and pilfer one it's been really really difficult yes we have stolen your air filter to attach the air filter to the turbo Gareth takes a corner section from the boost piping to make sure it can fit in the engine bay and to also create a collar so that the filter will fit on snugly I'm just gonna store it in a vacuum line in which we sort the start in earlier but then just went and had lunch no we didn't have lunch we we just went so we're using this nylon vacuum line because it's it's rigid it won't collapse under vacuum it won't expand under boost pressure and we just run that from the inlet manifold here all the way back to the east and a map sense and we showed you so we've got the nice hole in the back of the ECU where we took the screw out so we just run that pipe straight through the hole like so plug it into this bit the vacuum line now is plumbed into the maps editor so that gives easier the main reading than it needs to know and then the only other bit that needs to plug in with this ECU being such an awesome design are the two original plugs from the loom and they just clip straight in like so and in theory if the base map is good this car will start I'm gonna plug it in anyway just to make sure all the sensors are read in and that we've got the right information in the map and if I'm happy about that and I'm happy that it should be good to go then you get the drive home okay well we've got the lead already plugged in the ignitions on we've just opened up the ECU software they're mighty software so the first thing we look at is just to check we've got the right injector size in with 1800 that's there yeah that's right let's cool basically I'm just gonna go on to this screen if you let me and just have a quick glance over over all of the sensors and we've got the manifold pressure 97 kPa atmospheric pressure is somewhere around that and that's what we're expecting to see right now so that's good cooling temperatures 16 degrees we've got an intake air temperature sensor 20 degrees you know again it's it's it's kind of in the same area yeah that's pretty fine so as long as the battery you'll start the car you know we've dumped off I'm pretty confident we're good to go cool so this is it this is it turbo is done all that's left to do is put in some antifreeze put the sign on it back on fill and take him off the axle stands I'll be back at scores or soon to get the car dyno'd and Matt it is the end of day two here at the Autosport international show in Birmingham and Phil has now got a tow boat Nick from skuzzle-butt is massive massive massive thank you Mark as well and the hair Gareth thank you so much but all that's left to say is make sure you subscribe to the channel because I'm going to be driving this a hell of a lot and we're gonna do proper driving impressions proper noise one tire fires hug me hug me I mean I'm living your heck go on it make sure you subscribe it's it's now the end of the show people are packing up people are leaving and the engine is running so Phil now has a turbocharger everything works now I would like you to rev the nuts off it let's listen yeah so beau Phil done if you enjoyed this video because let's face it it was awesome and now Phyllis got a turbo make sure you download our Android app where you can see way more Phil's staff project mx-5 and just general awesomeness it's free and it's an awesome app and it's it'll just make your life more complete no more rust Colin's got rust

Channel: Car Throttle

Views: 1,075,046

Keywords: mazda mx-5 turbo conversion, turbo conversion, mazda mx-5 turbo, turbocharged mx-5, turbocharger, turbo, boost, mazda mx-5, turbo miata, project mx-5, miata turbo conversion, miata turbocharger, car throttle, carthrottle, alex kersten

Id: rVRgFw7Llvs

Length: 32min 56sec (1976 seconds)

Published: Thu Jan 28 2016