Project Porting! Pics!
 

So I'm kind of gunning for ~350whp on the stock 05 evo VIII turbo on pump gas. I do run alky injection, but I'm only running ~24psi so its really only used for a safeguard against bad gas (a lot of evo8 guys run 22.5 psi on pump gas, evo IX guys run almost 24!).

So, since this is my daily warrior, I am trying to keep it as reliable as possible. It has been tough, but I have yet to touch anything related to the turbo, or taking much apart.

This will end now. :) But, I am only planning on taking it apart once, and doing it right!

Here's where I started, with ~305whp. My car has HKS 280's, a TBE with a high flow cat, a upgraded FMIC, and the SMC alky kit.

http://www.scheides.com/albums/evo8/CHRIS1.sized.jpg

Re: Project Porting! Pics!
 

First thing's first, about 6-8 weeks ago I ditched the high-flow cat in favor of a testpipe. The change was semi-dramatic, with midrange torque feeling much better, improved spool, and high end power is definitely up a solid 10whp.

http://www.scheides.com/albums/evo-t...2128.sized.jpg

http://www.scheides.com/albums/evo-t...2129.sized.jpg

http://www.scheides.com/albums/evo-t...2130.sized.jpg

http://www.scheides.com/albums/evo-t...2131.sized.jpg
Look! A Turbo! LOL!

Re: Project Porting! Pics!
 

Next up is the o2 housing. This is a big thing for the evo guys on the stock turbo. At anywhere from $60-400, there's a ton on the market. Most are shyte, some are good, some are 'the best.'

The easy o2 housing to get now-a-days is the megan, and all the cheapos on ebay are rumored to be crap and cost cause boost creep (is this really a bad thing on a turbo that tapers anyways? meh...). Most on the market are supposed to be worth around 10whp, but buschur swears that this ebay (SSAC) housing that he ceramic coats and resells is worth a solid 15whp.

So please note, I'm not *saying* this thing is 'the best', just passing on info I've found and seen to be dyno proven on some of the bigger evo boards.

http://www.scheides.com/albums/evo8/IMG_2858.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2859.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2860.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2861.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2862.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2863.sized.jpg

Re: Project Porting! Pics!
 

Next step back in the exhaust side is the turbine housing. I purchased a $30 air-powered die-grinder and $5 worth of carbide bits. This will be used to lightly port my turbine housing. The 05 Evos have the big 10.5 turbine housing from the factory, so all that's really needed is to port-match the twin-scroll inlets, facing the exhaust manifold. I'll snap some pics of this when I do it.

Re: Project Porting! Pics!
 

My mom buys those red vines all the time :)

But that all looks good man.

Re: Project Porting! Pics!
 

Last piece on the exhaust side of the engine (save for the head itself) is the exhaust manifold. Buschur sells these puppies ported and ceramic coated for a decent price. This is supposed to be worth ~5-7whp. We'll see :)

http://www.scheides.com/albums/evo-t...2132.sized.jpg

http://www.scheides.com/albums/evo-t...2133.sized.jpg

http://www.scheides.com/albums/evo-t...2134.sized.jpg

http://www.scheides.com/albums/evo-t...2135.sized.jpg

http://www.scheides.com/albums/evo-t...2136.sized.jpg

http://www.scheides.com/albums/evo-t...2137.sized.jpg

Re: Project Porting! Pics!
 

http://www.scheides.com/albums/evo-t...2139.sized.jpg

http://www.scheides.com/albums/evo-t...2140.sized.jpg

http://www.scheides.com/albums/evo-t...2141.sized.jpg

http://www.scheides.com/albums/evo-t...2138.sized.jpg

As a comparison, here's a pic of how much material is removed from the twin-scroll outlet of the manifold, facing the turbine housing:

http://i22.photobucket.com/albums/b3...to-hotside.jpg
courtesy: Warrtalon

Re: Project Porting! Pics!
 

This will be about it for the hotside, dyno results to come on the 2007 MitsuStyle.com Fall Dyno Day!

Up next will be (hopefully) a ported intake manifold and ported stock throttle-body. The stock unit measures 59mm on the inside, and can be easily ported out to 65mm. Please note, 65mm = 2.5", same as my intercooler piping (and most everyone elses). The IM inlet is ported to match, and then the runners are port-matched for optimal power. These together are a dyno-proven 15whp+ on the stock turbo, so I'm hoping this will let me reach my goal of a super solid, mostly stock, DD.

Re: Project Porting! Pics!
 

I hope their dyno proven results aren't like the 15-25whp gains you are supposed to get from swapping FMICs on Evos.

Is the O2 housing really a ceramic coated SS autochrome unit?

Re: Project Porting! Pics!
 

Sorry I kinda posted in the middle of you explaining things. You can delete that so its not in the middle. But again that all looks nice. Hope you hit your goal.

Re: Project Porting! Pics!
 

Looks good, lets install it on Thurs!

Re: Project Porting! Pics!
 

Buschur is quite a salesman. The porting is worth something though, at least it was on the DSM's when we were doing this BPU stuff. :biggrin:

Re: Project Porting! Pics!
 

Ya, I hope so to. If not, it'll come back off and I'll go a different route :) I have no idea if these are really SSAC units, all of the 'good' ones have been on back order for months. Rather than take my chances with the various units on the market, I just decided to go with one that someone actually has 100% good stuff to say about them.

Whatever Mr. Going-back-to-small-turbo! Tons of fun to be had with a 16G and you know it! :)

Re: Project Porting! Pics!
 

That's awesome, but ahh, those numbers sound a little inflated.

That o2 housing looks like where the wastegate flow re-enters is really small, can that be enlarged?

Re: Project Porting! Pics!
 

16G is definitely a ton of fun, but EVO 3 for DSMs all the others not worth it, if i did it again i wouldn't have this one.
Looks like its time for you to make some big power, reliability is all in the tune and quality of parts used and maintenance, some dsmer has been running his car for the last year and a half making 600hp and 500tq.
Cruise should be good this year again. :smoking:

Re: Project Porting! Pics!
 

Squeezing every once of power out of that stock turbo arent you! haha

Re: Project Porting! Pics!
 

Update! This was a little delayed, as the o2 sensor was not super psyched about leaving the stock o2 housing, so I ended up replacing it :(

First off, BIG thanks to Chris Hughes (s2kracka) for overall help as well as some guidance with the porting I wanted to do. We ended up taking a bout 1-3mm (maybe 4mm on one side? I can't remember!) of of various portions of the twin-scroll turbine inlet. Nothing major, but in the end I would say it is definitely worth doing. Sorry I did not get a before pic, but here's after. We basically just gasket-matched it, just like the exhaust manifold is:

http://www.scheides.com/albums/evo8/IMG_2873.sized.jpg

[img]http://www.scheides.com/albums/evo8/IMG_2874.sized.jpg[img]

We also found a little lip inside the o2 housing that we decided to mow down just a little bit. Again, nothing major, just trying to smooth out exhaust gas flow:

http://www.scheides.com/albums/evo8/IMG_2878.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2879.sized.jpg

Re: Project Porting! Pics!
 

Here's one thing that floored me. Check out the stock vs ported exhaust manifold:

Stock:
http://www.scheides.com/albums/evo8/IMG_2868.sized.jpg

Ported/coated manifold by buschur racing:
http://www.scheides.com/albums/evo8/IMG_2869.sized.jpg
(hughes is confident he can reproduce this with some time and a bunch of porting bits)

Anyways, it is obvious that this is definitely worth doing.

http://www.scheides.com/albums/evo8/IMG_2870.sized.jpg
(sorry for no more close-up pics here, but the runners are port-matched, opened up a little bit each)

Re: Project Porting! Pics!
 

Install pics:

http://www.scheides.com/albums/evo8/IMG_2880.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2882.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2957.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2958.sized.jpg

http://www.scheides.com/albums/evo8/IMG_2959.sized.jpg

All buttoned up:
http://www.scheides.com/albums/evo8/IMG_2960.sized.jpg





Thoughts/Review:

Well overall, install for all of this, including doing the porting was right around 3-3.5 hours. Not bad at all, and I would say performance wise this is a big bang-for-your-buck set of mods. Turbo spool-up is improved, midrange torque feels stronger, and top-end feels good. My test-drive was out in the rain, so I'll update this tomorrow after I more through test.

Re: Project Porting! Pics!
 

Porting gains are nice, it certainly doesn't hurt, doesn't cost much if you do it yourself, and it's completely undetectable.

BTW, I didn't downsize, my package is on it's way from FP right now. :)

Re: Project Porting! Pics!
 

Steve's just going back to "old people" creature comforts. Couldn't hang with the young blood of little shits like me! But, don't get it wrong, the car will be just as fast as it's been. 12's...zing!
lol
-A. Swift

Re: Project Porting! Pics!
 

You either need to remove the heat shield and show of that pretty manifold, or get a cool looking stainless one. Just my 2 cents. Good job with the porting. It's always nice to see people getting their hands dirty and doing it themselves.

Re: Project Porting! Pics!
 

Ya I kinda like having the stock shield there. The silver shineyness underneath is a bit of a giveaway, but keeps things nice and stock looking. The purpose of the coating was to keep underhood temps down and heat energy in the exhaust gases going full-boar into the turbo, not for bling! :)

Re: Project Porting! Pics!
 

looks realy good

Re: Project Porting! Pics!
 

I like it how you have it. Porting is fun. Do you have all hard I/C pipes?

Re: Project Porting! Pics!
 

I understand the purpose of the coating, I just don't really like the way the stock heat shields look.

Re: Project Porting! Pics!
 

Looky what I got today! Time to start grinding again....

http://www.scheides.com/albums/evo8/IMG_0083.sized.jpg

http://www.scheides.com/albums/evo8/IMG_0103.sized.jpg

I've also added an OEM IX turbo to the mix of this project....

Re: Project Porting! Pics!
 

woot woot for the beagle

<<fellow beagle owner except mines a fat lazy bastard

Re: Project Porting! Pics!
 

Those pics are from a long time ago!

Re: Project Porting! Pics!
 

Ya that's my dog Turbo, he's kinda the site mascot at events and whatnot :) Beagles are awesome!

Re: Project Porting! Pics!
 

I just cleaned up my 14B last night. It really helps to use nice solid carbide bits. I "borrowed" them from school and they HOG through cast iron in no time. I then used a porting kit that consisted of sand paper drums to smooth out everything. Looks good!

Re: Project Porting! Pics!
 

I just figured out how to do an EGR delete using a standard DSM block-off plate and a quick hack to the stock ECU:

add to <romid>.xml file in EcuFlash:

<table name="ECU Periphery2" category="ECUPeriphery" address="fca" type="1D" level="1" scaling="Hex16"/>

Then change the value to '0xEDDF' for ECU Periphery2 in Ecuflash. Thanks to MrFred on EvolutionM for this. This will clean up my engine bay nicely!

I also just ordered some high-pressure throttle-body seals from works!

Re: Project Porting! Pics!
 

Way to pollute! j/k. I think that's awesome how you can go in an mess around with stuff in your ecu.

Re: Project Porting! Pics!
 

I got my intake manifold and throttle body back from buschur racing yesterday. There was a mixup and they shipped it a week after they told me they did, and before I could even think of complaining, they OVERNIGHTED it to me. I love those guys.

Here's some pics of the throttle body. This is just a stock TB that's been bored out to a full 65mm all the way through, and a new butterfly installed. Sitting next to the stocker it looks similar at the opening, but the stock one gets smaller as it goes thowards the butterfly.

http://www.scheides.com/albums/evo-i...5027.sized.jpg

This is bolted to the ported manifold, 65mm also. Wide open all the way through!
http://www.scheides.com/albums/evo-i...5028.sized.jpg

http://www.scheides.com/albums/evo-i...5030.sized.jpg

Next to the stock, unported TB. Same from the outside, but the butterfly on the left is bigger:
http://www.scheides.com/albums/evo-i...5103.sized.jpg
more angles:
http://www.scheides.com/gallery/evo-intakemani/IMG_5104
http://www.scheides.com/gallery/evo-intakemani/IMG_5105

Here is a rough comparison of the size difference between the 65mm stuff and the stock, unported manifold inlet (using my thumbnail for size reference):
http://www.scheides.com/albums/evo-i...5106.sized.jpg
http://www.scheides.com/albums/evo-i...5107.sized.jpg

Re: Project Porting! Pics!
 

Good stuff... proflow is doing some throttle body porting + new butterfly for the 4G as well... it's 250 including shipping I think and has proven gains of at least 5-6whp, one kid posted 17wtq difference in 4th gear on an auto as well.

Looks cool, if you don't mind me asking what does Buschur charge for that? So I can compare to proflow, and also what kind of gains are you looking at with it?

Re: Project Porting! Pics!
 

The intake manifold runners are ported out a bit as well, port matched to the head.

http://www.scheides.com/albums/evo-i...5108.sized.jpg

Again with the vague size comparison:
http://www.scheides.com/albums/evo-i...5109.sized.jpg
http://www.scheides.com/albums/evo-i...5110.sized.jpg

And some closeup pics of the portwork:
http://www.scheides.com/albums/evo-i...5034.sized.jpg

http://www.scheides.com/albums/evo-i...5035.sized.jpg

http://www.scheides.com/albums/evo-i...5037.sized.jpg

Re: Project Porting! Pics!
 

While I'm doing this, since I figured out how to remove the EGR checks in the ECU (see above post), I am ditching the EGR valve, the charcoal canister, and the lines associated with them. Should clean up the engine bay a little bit:

http://www.scheides.com/albums/evo-i...5039.sized.jpg

ditching this bracket as well:
http://www.scheides.com/albums/evo-i...5099.sized.jpg

Goodbye POS that cut the hell out of my hand!!!
http://www.scheides.com/albums/evo-i...5100.sized.jpg

Finally, an action shot of this little project....I love my 4G63 so much that I like to hug my engine and sing to it....'hold me closer Tony Daaaaannnzaaaaaa!!!!'
http://www.scheides.com/albums/evo-i...5087.sized.jpg

http://www.scheides.com/albums/evo-i...5088.sized.jpg

I stopped smiling soon after this, as I began dropping sockets and bolts into the subframe as I began to install the new manifold. I then broke off one of the bolts in the head, what a fcking b*tch of a job. Oh well!

Re: Project Porting! Pics!
 

looks good

Re: Project Porting! Pics!
 

This is just a basic port job on the intake manifold, porting the runners and boring out the inlet to 65mm was $75. The TB conversion/boring was $300, I could have had it done for $300, but I would not have done this if I had not seen Dave Buschur post the solid whp gains from this little project, so I commited myself to give my money to him, instead of the other guys undercutting him and posting zero proven power gain results.

I am expecting a SOLID 15whp from the IM/TB combo, through the entire rev range. This will complete my porting project. With the exhaust mani (5-10whp), SS o2 housing (10-15whp), and this, I am hoping for a full gain of 30-45whp. My car made 295whp on just pump gas, so I'd expect ~330whp. I also bolted on the Evo IX turbo though as well, which is rumored to be upwards of +20whp, so I have set a semi-realistic goal of 335whp on straight pump gas, and have lofty dreams of 375whp with alky. We will see when I re-tune this thing.

Re: Project Porting! Pics!
 

So you have the know-how on going into your EcuFlash and changing properties and values? Or were you grabbing information gathered elsewhere? That's pretty frickin' awesome that you are able to do that stuff in the ECU on them things.

Looks like you're going to have yourself a sweet ass sleeper in the near future with some good power!