First off let me thank Demon for the hosting since my internet has been very screwed up since Friday. While I am at it I'll thank him for going through all the numerous semi-professional discussions that we have had on the various choices that were made on this and OTHER
projects!
Thanks Greg!
Suneil, You know exactly where my old TB is, your car!
I haven't had time to fab up the other one yet.
The important specs are listed so I won't go over that again. I just want to put out a little theory and reasoning as to why I did this setup.
1.) I did it because I wanted to try out new things and learn some stuff. I did it because it is my hobby and I love it.
2.) I made some of the choices/compromises that I did for the good of CEG; you'll see where that comes in shortly.
3.) Last (but not least
) I did it to shut some Mofo's up and prove a point or three of mine.
Intent:
a.)To prove/show that the stock 3L component system is capable of supporting X amount of power.
b.)To prove that on a limited budget you can enjoy this system if you are willing to do just a little legwork and labor on your own!
c.)Set it up for future CEG'rs to order these types of parts/supplies so that the DIY'r can build this setup.
I took a low-mileage 3L engine and went through it to clean it up. I put in clevite rod bearings but left the mains alone. I used stock Rods, stock pistons, and stock rings.
I prepped it to fit the MTX-75 and run the 2.5L alternator and SVT oil/water cooler.
Then I prepped the heads with minimal porting to fit to the 2.5L manifolds. This required about 3 hours of hand porting the oval into a sort of figure 8 inlet that matched the 2.5L LIM. Then I used JB weld with some prep work to create a little bit of a material so that the LIM would match the head better. Then I cut off the tabs on the LIM gaskets and used silcone to seal it in place on the head.
For the exhaust I ran a gutted 2.5L rear exhaust manifold and the modified escape front manifold. THe front manifold had the cat section cut off and a piece of pipe with a turn going the other way was welded onto it. All upper and lower O2 sensors were retained.
Next I made a crossover pipe based upon all the knowledge I had gained from the previous turbo project.
The downpipe that I made was retained from the last turbo setup.
The intake system is essentially unchanged except for the MAF. I used the Lightning MAF with a large K&N filter for the lightning screwed onto it with a small adapter plate sandwiched in the middle that just covered up some uncovered section when the maf was screwed to the filter.
It is the same type/operation as the large Pro-M MAF/filter combo that I had but less total airflow capability.
The chip is unchanged from the last turbo setup except the MAF transfer function.
What this means to you is that you can use stock manifolds and modify the front to fit this crossover pipe. Decently prep a 3L motor, 2000+ escape is the easiest and either retain the 3L intake system or go with contour intake system.
Then you order your choice of turbo and wastegate, T3 exhaust is the flange I used along with the 38mm Tial.
Get 36# injectors for return-style systems, 39# injectors for the return-style systems.
A lightning MAF.
Then you go to StreetFlight and ask for a chip, an intercooler (if you are smart) and intake piping if they have it for a T3/4 turbo.
Prepare to shell out some cash, but not anything crazy.
After this you walk away with pretty much what you see in the dyno sheets.
MSDS header owners will be pleased to note that they can retain their MSDS headers, adapt only the front header to fit the crossover pipe and end up with even better numbers than I have here!For those who are planning this out, you can just order the headers during the build-up.
OR, you can just order the full stainless version of the SF kit for the highest performance.
However, I want everyone to know that this is just another way to accomplish getting lots of power, not a better way.
Vortech owners, SF owners, nitrous, these are all other ways.
I just wanted to prove that simple log style manifolds with crossover pipes, turbo, basic cams and the
STOCK DURATEC ENGINE IS INDEED A WELL BUILT, PERFORMANCE ORIENTED MOTOR!Other things you need to know:
This was on 93 octane fuel commonly available here in TX. It is in full street trim with a tuned A/F ratio of 12.3-12.5:1
No detonation was observed.
In all honesty the engine could probably easily survive 14 psi with a good tune.
If anyone is interested in the crossover pipe for the T3/4 turbo then we need to do an interest check in the group buy forum. If there is enough interest in a group buy then the local performance shop named Deepstage is considering building a crossover pipe. Approximate price will be around $700 initially IF there is enough interest and IF they agree to do it. My crossover pipe will be used as a model to build a jig for reproduction. After the initial offering the price will drop but how much is not known since it may/may not happen.
Enjoy.
I can't wait to see what you do when you have it setup more to your liking and fine tuned 
