Blown to Boosted, The Build Thread. *PIC HEAVY*

[Sean-Himself]

Spent a better portion of my day chasing my over boost issue. I removed the WG and opened her up. Everything looked fine, no visible tears, all the bolts were tight, no holes in the vacuum line (directly to the turbo). Assuming it was the Ebay-ish WG I got frustrated and got some lunch... After, I thought... "hmm, I'm going to fill up the air compressor and see how much pressure it takes to open." 30psi later, didn't open (4PSI WG spring)... hmm... I then removed the vacuum line and T fitting on the side of the WG and blew air through there to make sure it was clean... To complete surprise, blocked... I inspected the T fitting and found this...

2019-01-01_05-01-57 by Sean Miller, on Flickr

Thanks EMUSA.

Now to re-test.

Also, Not 1 knock code has shown up since I overboosted the first time. Odd

 

[gamefreakgc]

Spent a better portion of my day chasing my over boost issue. I removed the WG and opened her up. Everything looked fine, no visible tears, all the bolts were tight, no holes in the vacuum line (directly to the turbo). Assuming it was the Ebay-ish WG I got frustrated and got some lunch... After, I thought... "hmm, I'm going to fill up the air compressor and see how much pressure it takes to open." 30psi later, didn't open (4PSI WG spring)... hmm... I then removed the vacuum line and T fitting on the side of the WG and blew air through there to make sure it was clean... To complete surprise, blocked... I inspected the T fitting and found this...


Thanks EMUSA.

Now to re-test.

Also, Not 1 knock code has shown up since I overboosted the first time. Odd

Wow. Good thing you caught that before something bad happened.

Knock codes are for knock sensor malfunctions only. If you get severe knocking/predetonation the ECU will just try and pull as much timing as possible, but obviously there's only so much it can do so that's a real danger.

 

[Sean-Himself]

Wow. Good thing you caught that before something bad happened.

Knock codes are for knock sensor malfunctions only. If you get severe knocking/predetonation the ECU will just try and pull as much timing as possible, but obviously there's only so much it can do so that's a real danger.

Yeah, I never had an issue with knock sensors when it was supercharged. Only since I went turbo it has been an issue. From what I've been reading, it is almost guaranteed you will get knock codes on a turbo 5vz. They just don't like being turbo'd for whatever reason

 

[Sean-Himself]

Just thought I would update. I have cleared up pretty much every little issue that was having (knock sensor codes, over boost and a random jerking/dead spot). Been driving it around at 6PSI without issue for over 6 months now. I have plans to change the turbo (for better spooly noises) and dual stage boost controller. I was also finding that the 1st-2nd shift was getting soft, so I installed the transgo 340 HD2 shift kit. Since clearing up the issues some friends and I decided to buy tools to build some bumpers. I recently finished my front bumper, turned out better then I anticipated. Will be starting the rear bumper soon! Below is just a few pictures of the runner and the bumper :cowboy:

20190326_185522 by Sean Miller, on Flickr

20190327_184431 by Sean Miller, on Flickr

20190327_182931 by Sean Miller, on Flickr

My buddies Runner is also turbo!
20190302_135516 by Sean Miller, on Flickr

 

[Sean-Himself]

I had nothing but bad experiences with the Auxbeam spot light pods (super chinese lights, I know)... But, I pulled the trigger on some Element LED amber cannons and wow.. What a difference. Picture comparisons below...


Element LED on the left (2000 Lumen)
Auxbeam spot pod on the right (2000 Lumen)


20190124_171637 by Sean Miller, on Flickr


Both amber cannons on

20190128_062840 by Sean Miller, on Flickr


Auxbeam "2000 Lumen" on the left VS my Streamlight 500 Lumen flashlight on the right...

20190125_174833 by Sean Miller, on Flickr

 

[Sean-Himself]

I then started the tube bumper trek. I have never fabricated anything to this extent so it was all trial/error but I thoroughly enjoyed it! I first cut and made mounts for the frame end rails and then cleaned/painted the radiator support. I made some renderings of bumper styles on Microsoft Paint.... LOLZZZ... Then went to work.


20190705_202338 by Sean Miller, on Flickr


20190719_192121 by Sean Miller, on Flickr

20190721_183815 by Sean Miller, on Flickr

20190725_173409 by Sean Miller, on Flickr

20190726_182615 by Sean Miller, on Flickr

 

[Sean-Himself]

Since the turn signals were integrated into the bumper, I purchased some flush mount LEDs and wired them into the headlight filler panels.

Note: Click on the image to see a short video of them

20190712_212917 by Sean Miller, on Flickr

 

[Sean-Himself]

Just an update to this dead thread.

I made some retrofits!

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[quicksilvr]

Sweet project! I just looked through most of the pics on flickr, and started following you on there!

I'm intrigued by your knock sensor setup that you have a couple pictures of right before the bumper build pics started. Care to expound on what you were able to do with that setup like that to sort out the knock codes?

 

[Sean-Himself]

Sweet project! I just looked through most of the pics on flickr, and started following you on there!

I'm intrigued by your knock sensor setup that you have a couple pictures of right before the bumper build pics started. Care to expound on what you were able to do with that setup like that to sort out the knock codes?

I will slowly be adding to the Flickr file as I continue along, I have a 7 week old at home that has been eating up my free time so progress has become very slow lol I am hoping to start attempting to build a rear tube bumper before long but we will see.

My knock sensor issue was a massive headache. Back when I had my supercharger I had replaced the knock sensor harness kind of as a "since I'm in here" type of thing. Never had knock sensor issues while supercharged but as soon as I got the turbo setup running I would throw a code at least every other drive. It was very annoying. Just from research I had read that 5vz turbo setups do not agree well with the factory sensors, which I found very odd because I had no signs of detonation or pinging with the turbo setup but I constantly had pinging issues with the supercharger... I then found that GM knock sensors aren't as "finicky" as the Toyota sensors. They have a larger range. So, since I didn't want to pull the lower intake I made a mount for 2 new GM sensors. It helped reduce the number of times the knock codes would come back but I would still get them about once a week at random. Sometimes it would be a bank 1 code, sometimes a bank 2. I replaced the GM sensors just in case I received a bad batch but no luck (they are only like $25 each) Once day I had a random thought that maybe my little mount (off the intake) had a vibration resonating through it triggering my knock codes. I then pulled the engine hanger mount and tapped it for the knock sensors, I used this mount it was a thicker material and was bolted down in 2 places. I extended my sub harness and like magic, no more codes!

 

[quicksilvr]

I will slowly be adding to the Flickr file as I continue along, I have a 7 week old at home that has been eating up my free time so progress has become very slow lol I am hoping to start attempting to build a rear tube bumper before long but we will see.

My knock sensor issue was a massive headache. Back when I had my supercharger I had replaced the knock sensor harness kind of as a "since I'm in here" type of thing. Never had knock sensor issues while supercharged but as soon as I got the turbo setup running I would throw a code at least every other drive. It was very annoying. Just from research I had read that 5vz turbo setups do not agree well with the factory sensors, which I found very odd because I had no signs of detonation or pinging with the turbo setup but I constantly had pinging issues with the supercharger... I then found that GM knock sensors aren't as "finicky" as the Toyota sensors. They have a larger range. So, since I didn't want to pull the lower intake I made a mount for 2 new GM sensors. It helped reduce the number of times the knock codes would come back but I would still get them about once a week at random. Sometimes it would be a bank 1 code, sometimes a bank 2. I replaced the GM sensors just in case I received a bad batch but no luck (they are only like $25 each) Once day I had a random thought that maybe my little mount (off the intake) had a vibration resonating through it triggering my knock codes. I then pulled the engine hanger mount and tapped it for the knock sensors, I used this mount it was a thicker material and was bolted down in 2 places. I extended my sub harness and like magic, no more codes!

That's awesome, and good thinking. I have some pinging issues with my supercharger, but have not once thrown a knock code for detonation. But I did have to tear the whole thing down and replace both sensors and the wire harness when the harness went bad. That's the only time I've seen a knock code....and yet I detonated bad enough one time to break a spark plug. It's a mystery.

My brother is thinking about doing a turbo on his '96, so this info is super helpful if he runs into the same issue.

 

[Sean-Himself]

That's awesome, and good thinking. I have some pinging issues with my supercharger, but have not once thrown a knock code for detonation. But I did have to tear the whole thing down and replace both sensors and the wire harness when the harness went bad. That's the only time I've seen a knock code....and yet I detonated bad enough one time to break a spark plug. It's a mystery.

My brother is thinking about doing a turbo on his '96, so this info is super helpful if he runs into the same issue.

Dang! Took out a spark plug huh, impressive. I always had the impression that the supercharger was this amazing bolt on power adder and honestly it left me disappointed, especially for the money. I ran a 2nd gen charger with a 2.1 and 7th.

Now, the turbo setup... Not nearly as easy to install but I have yet to be disappointed a year later. I also just recently made a manual dual stage boost controller so I can have either 6psi or 12psi at the push of a button

 

[quicksilvr]

Dang! Took out a spark plug huh, impressive. I always had the impression that the supercharger was this amazing bolt on power adder and honestly it left me disappointed, especially for the money. I ran a 2nd gen charger with a 2.1 and 7th.

Now, the turbo setup... Not nearly as easy to install but I have yet to be disappointed a year later. I also just recently made a manual dual stage boost controller so I can have either 6psi or 12psi at the push of a button

Haha, yeah thankfully it was just a one time event and not something I fight with all the time. I had just installed a URD AFR calibrator that is "supposed" to add fuel in closed loop, so I took a steep highway hill in high gear and tried to make it detonate like it historically always would. And it still did, in catastrophic fashion. The URD box does seem to help around town, part throttle lower gear...but on the highway in high gear, it doesn't add near enough to overcome the load and keep the AF/R in a healthy range.


But I agree 100% on the supercharger thing. Compared to a good turbo, they are not great. I'm hopeful that my brother will go ahead and park his truck and start a CX racing turbo kit install. I think we need to finish the MS3Pro megasquirt upgrade on our turbo Neon project first.