99mx5

I'm finally adding a turbo to my car. I bought a supercharger when I used to autocross. I then started to race on a track. Everything was great until I blew up the blower. I removed it then continued to race naturally aspirated. I eventually became a better driver without the boost, so now its time to add boost again.

So far I have added:

-Enhanced DIYPNP MegaSquirt
-Precision 600 intercooler
-ACT clutch and street disc
-TEIN Flex coilovers
-PWR radiator
-SS clutch, brake lines
-Carbotech XP10 and XP8 brakes
-Boss frog rollbar
-Custom CAI airbox
-DIY coolant reroute upper and lower
-PS delete with welded input shaft
-Ultrashield Rally Sport seats
-Simpson camlock harnesses
-Squaretop manifold
-COPS
-Walbro 255HP
-Other smaller details that I forgot

I contacted ARTech for SS coolant and oil lines, a top mount ramhorn manifold, 3" SS DP and exhaust with Magnaflow resonator and muffler. I purchased a BorgWarner EFR 6258 and sent it off to him.

Here are the pics of his progress...

99mx5

I ordered a CXRacing intercooler kit. The plan is to have the pipes welded locally.

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Here is my DIY coolant reroute to make space for the turbo and improve cooling on the track. I made the parts from a broken aluminum racing jack. The upper reroute improved cooing across the engine and the lower reroute makes more space for the turbo manifold.

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More fab pics of the stainless 3" exhaust. It has a Magnaflow resonator and muffler.

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Stainless braided teflon oil and coolant lines were made. I eventually ended up routing them differently due to space constraints.

99mx5

I was getting close to receiving this kit from Abe. I know that there will be lot of small parts that I'll need to install it.

I have the following:
-wideband (I forgot to put it in the first post)
-intercooler piping with clamps and couplers/elbows
-GM temp sensor
-intercooler
-oil and coolant lines and hose

I'll need:
-mount intercooler
-temp sensor bung
-duct airflow
-make oil/coolant line bulkhead bracket
-heat shields for brake booster/manifold
-tubing for the blowoff valve
-wastegate actuator tubing
-larger fuel injectors
-drill oil pan (need drill bit and tap)
-oil catch can ?
-intake hose routing
-boost control ?
-??

I also decided to get fire sleeves for all the lines going to and from the turbo for extra protection.

I found them here: http://208.109.215.220/files/newprod.pdf

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The turbo lines arrived after most of the turbo parts, due to being outsourced.
Here they are when I received them. Somebody got in the way as I was taking a pics.

All of the parts are steel. I used a steel BSP to NPT fitting for the block and a steel tee and a steel NPT to -4AN fitting for the line. The VDO oil pressure sender connects to the tee.

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Here is a pic of the Precision 600 intercooler.

99mx5

I painted the manifold with VHT ceramic paint and baked it to cure it.

99mx5

The scariest part of the build was to drill the oil pan. I put a ring of tape on the bit to act as a stop so that I would not hit the oil pickup tube. I also greased the bit so that it would catch the metal shavings.

In order to keep the tap straight to cut the threads, I put it in a socket with a long extension. It worked perfectly. After I cut the threads, I used JB Weld to seal it to the oil pan.