You must be one of those too stubborn to listen to other people's criticism.

Seriously...
You plan is a royal waste of time and money for most people.
Please go read Corky Bell's "Maximum Boost".
Your new wastegate pipe entries are very inefficient - 90-degrees perpendicular to the actual exhaust gas flow.
(If you had gone with the S4 turbo exhaust manifold, there is already an angle built into it, and you would've had a more efficient and easier time doing this same procedure.)
Corky Bell also talks about how keeping exhaust flow between the two turbine passages can be advantageous.

If you think I'm just spewing sh*t out of my ass, then so be it.
If you think I have some personal beef with you, then so be it.
(Seriously, it's nothing personal.)
I'm trying to correct some of your misconceptions of what you're trying to do and warn others of the shortcomings.
If you don't have the openmindedness (is that a word?) to see that, well, then I wish you good luck with your project...


-Ted

I'm not here trying to break records. I'm just tying to have fun with my hobby. I have read a lot of stuff you written in the past, and learned from it. The way I learn is by doing. There's to much reading and not doing these days with a forum for everything known to man. Experience is the best teacher.

I did not do butt loads of research or map out my design for best-of results. I used stuff i had on hand and made it work.

No i don't think you have some personal beef with me.
No i don't think you your just spewing shit out of your ass.

No it's not a word, it's two words - open mindedness

Basically what i am saying is, Give me criticism yes, but damn... Don't always aim to hurt my feelings, I'm emotional. lol

All done... Fits nicely. I will not be able to "test" the car until a week from now. I will be in Costa Rica for 7 days! Little vacation time for me...

I'll update once I'm back...

http://i282.photobucket.com/albums/k...anifoldh-1.jpg

http://i282.photobucket.com/albums/k...anifoldg-1.jpg

Update:

I finally installed this on my car. I can hold boost all the way with no problem now. Another problem I was having was with my 2-step launch control. The car would not build any boost even at 6k rpm. Just tested this and easily build boost off the line.

Proving further that the stock wastegate door in the turbine housing is being forced open prematurely by exhaust pressure. Porting the wastegate can just make this even worse. EBC's will NOT fix this, at all.


:icon_tup:

Here's the Russian's POV:

with all the money it takes to port te stock wastegate, buy OEM turbo gaskets ($180) and have BNR rebuild your 20yo journal bearing turbine (the S4 stage 4 rebuild is $950)

After all this, you still have a journal bearing turbo, really old design technology, and a cast iron turbo that sits extremely close to the intake manifold.

Why not just get a tubular cast or welded manifold, and a brand new ball bearing turbo that you KNOW will deliver power and be reliable. The price difference is not much, it's new parts...

The twin scroll twins from the FD I can understand, but the FC's stock turbo is just such a piece of junk it seems.

I have to agree with ted.. it would be better to do this with a S4 manifold, since you are negating the affects of the S5 independent twin scroll. the exhaust pulses mix at your wastgate connection. maybe if you use dual wastegates, one for each line?

My main reason? I want to run 12.99 (12.50's is a dream goal) or better on the stock turbo, motor, ECU, top mount, ect... Open my hood, and it still looks pretty stock. But now that I got this set-up, I can run 12's for sure. I'll be at the track real soon to make that a whole truth, not an assumption.

Another thing is, the cost of this set-up for me was basically nothing. Just stuff i had laying around. Also, I have built hybrid turbos from the stock turbo for under 200 bucks that are capable of 400whp on a TII. Aftermarket manifolds are easily 200 bucks for a used one, and a nice ball bearing turbo is 1000 and up easily. And you still have to have a custom downpipe, oil feed/return, ect... Get's pricey and complicated for the average person. Hybrid turbos are just so easy, and unless your trying to set records, anything more is just overkill.

The s4 manifold would have been easier to do from a fabrication standpoint, but the outcome is still the same. It works, and it works flawlessly. I know this because I have done about 20 pulls on it so far and tested the 2-step numerous times.

Just because something is easier, does not mean it's better. It's usually the other way around. I recommend this to anyone who is having problems holding boost to your shiftpoint or having boost spikes. Forget about porting the wastegate... add an external wastegate to your stock manifold and you'll see how happy you are with it for yourself.

I noticed you're using one of those piece-of-shit Turbonetics wastegates...
Keep an eye on the sleeve that isolates the rod actuator from the diaphram housing.
It tends to get loose and jam the wastegate.
Easy fix is to stake the sleeve into the housing so it doesn't get loose.

Good luck,


-Ted

update!


I made a new downpipe to clear the wastegate a little better. Then I was like "man, all this piping for what". It dosnt really make the car any quieter. So I dropped the entire exhaust and just welded to muffler to where the downpipe would normally end. Barely any louder. And dropped even more weight off the car.

The car sounds much deeper and better to me. Others say the same thing that have seen it in person. I'm guessing the manifold porting added to the better sound at least a little. The car spools twice as fast and I can even here the turbo spooling through the exhaust now. Sounds dope... But what beats that easily, is the sound of the wastegate when that big bitch open up! lol... scream crazy. And best of all, It holds boost easily anywhere I want it to all the way to whatever RPM I feel like taking it to... dopeness.

Before this, I could go through 1st, 2nd, and 3rd gear with out barely breaking the tires loose on the street. Now there's no hope for the tires in 1st, same for second. And third the tires are still smoking. I even tried rolling at about 45mph and ease in on the throttle, still lights the tires up! And these are 255 wide tires.... So did this help? Fuck yeah, like you wouldnt believe...

Oh ,and by the way, I havnt tuned the Apex-i NEO at all. Nothing. All of this with ZERO tuning. Now that I have a wideband back and have a second o2 bung in the downpipe, I can actually tune the car. It's only getting better.

Pics of everything installed!



http://i282.photobucket.com/albums/k...D/SAM_0409.jpg

http://i282.photobucket.com/albums/k...D/SAM_0407.jpg

http://i282.photobucket.com/albums/k...D/SAM_0406.jpg

http://i282.photobucket.com/albums/k...D/SAM_0405.jpg

http://i282.photobucket.com/albums/k...D/SAM_0411.jpg

http://i282.photobucket.com/albums/k...D/SAM_0404.jpg

http://i282.photobucket.com/albums/k...D/SAM_0416.jpg

I've done a few S4 t2 manifolds with a rerouted Tial 38mm, perfect boost control...

your neighbor must love you .:cuss:....looks cool anyway:icon_tup:

The car really isn't loud, so it dosnt really bother the neighbors. It's really one of the quietest Rx7's I have ever owned. This was done by spending 2 months searching for the perfect muffler. It's the only one I use now.

no way...good to no. i live near a dunkin donuts . i have to drive two extre blocks to avoid the rollers.

Hushpower?

The reason why exhaust are piped back toward the rear is carbon monoxide poisoning.
Please be careful if you're going to keep the exhaust like that permanently.


-Ted

Yes, it's a Hushpower.

I do not start it in the garage ever and it has a turn down on it. Many V8 cars have it the same way. Thanks for caring though! It must be a Christmas thing...