Contour Enthusiasts Group Archives Forums Modifications Zetec Maintenance My Zetec Cougar homeade turbo dyno run with video

I've posted in the focus forums a bit since they have more people with experience turboing zetecs I felt(and I just completely forgot about the CEG forums). One of they guys there lives in San Antonio and invited me to go with him to a dyno run with him and a half dozen F150 Lightnings.

We got there at 11:00a.m and they told us they would dyno us front wheel drives around 2, or 3:00pm. Since I sleep during the day this was no good for me. So I went back home and had my dad come back with the car to do the run.

Did two runs, back to back.

Run 1: 144.3 Hp @ 5300 rpm and 156.3 Lb/ft @ 4400 rpm
Run 2: 141.3 Hp @ 5000 rpm and 152.6 Lb/ft @ 4500 rpm

I'm not sure about what peak hp/torque rpm was since I wasn't there and the printout lines are the same color. I'll ask my dad if he knows.

In the first run it looks like the torque peaked quick at 150@2900rpm then 156@4400. Horsepower looks like it didn't peak until 5300. The torque line stays pretty even between 3000 and 5000rpm. Horsepower looks like it gradually goes up til it peaks at around 5000.

They figure with 16% loss it comes to around 167hp at the flywheel. I can live with that for now.
The owner of they dyno who was behind the wheel for the run said that past 5500 rpm I start leaning out big time. So I guess I'm not going past 5500 anytime soon.

I'll try and post the printout and video within the next few days. Over all I'm satisfied, for now.
http://www.axs4u.net/home/louiem/dynorun.mpg
I've posted a bunch of updates in the Cougar forums. If you want to read more about go to those forums and click on the zetec and forced induction forums.
http://www.fastcougar.com/forums/
--------------------------------------------------

2000 Rio Red I4 Cougar
IHI RHB5 Turbo at 5/6 psi
Sawed-Off Short Throw Shifter
Freedom Design Strut Tower Bar
17" ZN Wheels and Tires

Roush Springs to be installed
42 lb/hr injectors and 70mm Pro-Flow MAF to be installed

Looks like you need to tune Big Time, but massive props for building your own!!!

Yeah!! Nice job on a home-made turbo. Any tips/ideas you want to throw out there for the rest of us?

For tips just do a lot of searches on the web for turbo info.

The basics are simple. All you need is a turbo, an intercooler, some pipes metal and rubber, an oil line, maybe a water line and a lot of clamps.

You bolt the turbo the the exhaust manifold, hook the downpipe to the exhaust, hook the intake into the intake of the turbo, route the outlet of the turbo into the intercooler and hook that up to the throttlebody.

Of course it's MUCH EASIER SAID THAN DONE. All that took my dad, a twenty years experienced mechanic(although no turbo experience), two months to do. Everything had to be done from square one and he had to learn as he did it.

As for having it custom done, I didn't want to spend $2000 or more for a custom build bolt on kit and get only 50 hp. I read some articles on the web about do-it-yourself twin turbo installs for less than $1000 on Mustangs so I figured I could get a single turbo done for less than that.

So for tips just do web searches and read every article you can on the web or magazines on turbo's.

Dude that chit was crazy. All you got to do is tune. It still sounds nice for not being tuned yet. I love the turbo whistle.

Since nobody asked, what do you mean by "homemade turbo". Did you take it off another car, how much did it cost, is it possible for other people to do the same thing?

I must have a turbo, I just love that noise!!

Very nice...congrats on the build. You should look into installing a Apex-i SAFC to pump more fuel in above 5500rpm. If you want I have a wiring dia. from my focus install....

It's homemade in the sense that all the parts except the turbo and intercooler were custom or handmade. It was not swapped from another car.

The exhaust manifold was custom made, cut, and welded. The intercooler and intake plumbing is 2 1/4" exhaust pipe, pre-mandrel bent and cut and welded and clamped into place.

The turbo was purchased used on Ebay for $101,shipped. The intercooler was purchased at a pick-n-pull for $25.

All the parts cost just under $800, with labor done free by my dad.

Anybody with technical automotive knowledge can do their own custom turbo. Unless you have a shop worth of tools, or acess to them, it would be more difficult.

Here are the scans of my dyno charts.

Run 1


Run 2

So far the stock computer is doing an OK job of controlling the fuel up to 6000 RPM. I have 42 lb/hr injectors and a 70mm MAF but I can't run them until I get something to pull timing.

The cheapest solution would be to get a custom programmed Diablo chip. I just need to get off my butt and fill out and mail out the form for a custom program. Those 42s aught to be good for over 200 hp at the wheels.

--------------------------------------------------

2000 Rio Red I4 Cougar
IHI RHB5 Turbo at 5/6 psi, Sawed-Off Short Throw Shifter, Freedom Design Strut Tower Bar, 17" ZN Wheels and Tires

Roush Springs to be installed

Not bad at all. Keep it up.