2004 Hatchback 2.0L Turbocharged "Build Thread" for 2011

[Nemasys]

As most of the veterans of the forum know, I have a 2004 Hatchback with a swapped 2.0L engine that I turbo'ed last year. For the new guys, oh yes I'm not joking haha!

Althought that was posted on the forum, I really did not get into details on what I did and I didn't post many pictures.

I would like to go in much more detail this year and post a good work log of my car over this spring and the summer.

Now I know how quickly a thread can get out of hand or off topic, so I would like to ask the community to please stay on topic, if you have any questions feel free to ask. I won't start from scratch and explain everything I did again so if you have a question on a specific thing, please ask!

I would like this thread to have as much information as possible so that anyone looking can easily get access to it in case they would want to start such a project.

Thank you for looking and your cooperation for staying on topic.

-Nemasys

[Nemasys]

I'm going to start off by listing every modification and addon that has been done to the car since I bought it:

Performance:
- Complete 2.0L Engine Swap
- 2.0L 5-Speed Transmission
- Custom Turbo Kit:
> T3/T4 T04E .60 A/R Intake and .63 A/R Exhaust Turbo
> HKS SSQV Blow Off Valve
> OBX 38mm Charge Side Mounted Wastegate
> 2.5" Aluminium Piping with Front Mount Intercooler
> AEM UEGO Wideband Gauge
> iEquus Boost Gauge
> Megasquirt v3.57 Engine Management System
> 3 x 32 Lb/Hour Extra Injectors
- NGK Iridium Spark Plugs
- Optima Rep Top Battery
- OBX Oil Catch Can
- Apex Lowering Springs - 1.5" Drop
- Two Coils cut on each of the Apex Springs - Extra 2" Drop
- Urethane Filled Transmission Mount
- 360 Dynamics Short Shifter
- 205/40ZR17 Performance Tires
- Sun's Hyper Voltage GT System
- Sun's Hyper Ground System

Interior:
- Ractive Racing Seats
- Custom Floor Mats
- Isotta Aluminum Shift Knob
- Painted Door Panels and Dash in White
- Painted Center Console, Center Floor Console, A-Pillars in Red
- Removed Rear Seat
- US Speedo White Faced Gauges
- iEquus 10k RPM Tachometer with Shift Light

Exterior:
- Black Projectors
- DDM Tuning 6000k 35 Watt HID Kit
- Black Altezza Tail Lights
- Clear Side Markers
- 80% Front, 20% Rear Black Tinted Windows
- Painted Calipers and Drums in Red
- Custom Silver Strippe
- Painted Bug Deflector, Front Grill, Bowties in Silver
- Added "SS" Badges
- Motegi Racing DP12 17" Silver w/ Polished Lip Wheels

In Car Entertainment:
- Pioneer Premier DEH-P8MP Mosfet 60W x4 Deck
- Sony XPlod 6x9" 320Watt [80Watt RMS] Rear Speakers
- Sony XPlod 6 1/2" 270Watt [55Watt RMS] Front Speakers
- Sony XPlod 1300Watt [380Watt RMS] 12" Subwoofers [x2]
- Alpine 600Watt Two-Channel Mono Amp

[reddemonx92]

Hey nemasys i have a question about your interior. How much did it cost you to get the dash and doors redone or did you do it yourself at home?

[Nemasys]

Last year playing with the stock ECU and Megasquirt in piggy back mode, I tried to use my 1.6L ECU so my coolant and fuel level gauges would work correctly.

Turns out the 1.6L's has different ignition timing and that resulted in a headgasket failure, so no more 1.6L ECU

Since then I have bought a Cometic MLS headgasket which will be accompanied by a set of ARP headstuds that I am buying next week!

Heres a pic of the gasket:

[Nemasys]

This year I'm going a slightly different route then last. Instead of running the car's fuel injection completely off Megasquirt, I'm going to run the car on the stock injectors and ECU and use 3 extra 32 pound injectors welded into the intake manifold.

These injectors will only operate under boost, during vaccum and normal driving conditions, the stock ECU and injectors will handle the fueling needs.

This also means I have no start-up enrichments to tune, no acceleration enrichements either since they are all controled by the stock ECU, makes things way easier. Simply put, its like driving a regular non-turbo car until the boost hits!

Here's a pic of the injectors I bought used from a friend:



I'm using 3 injectors because at 10 psi and above I'm affraid of topping out 2 injectors, so I'm playing it safe. Rather have 3 injectors at 50-60% duty cycle then 2 at 90-100%. I have a 4th one in case 1 has a problem.

[Nemasys]

Hey nemasys i have a question about your interior. How much did it cost you to get the dash and doors redone or did you do it yourself at home?

I did them myself with some exterior plastic paint (like paint for plastic lawn chairs, etc) that I found at my local hardware store. I took the door panels off but the dash was painted right there inside the car with a paintbrush, yes a paintbrush! I masked the things I didn't want paint on and away I went.

Cost was the quart of paint, maybe like 10 dollars and the brushes, plus the 3-4 hours it took to paint it.

[RoRo]

Very nicely done so far. Could I trouble you for information about the short shifter? I hate the stock shifter and would love to buy a short shifter for this car. B&M used to make one, I bought that one for the '05 when I had it, but they stopped making them.

Oh and one suggestion, that stock steering wheel looks wayyy out of place in your interior.

[Nemasys]

Very nicely done so far. Could I trouble you for information about the short shifter? I hate the stock shifter and would love to buy a short shifter for this car. B&M used to make one, I bought that one for the '05 when I had it, but they stopped making them.

Oh and one suggestion, that stock steering wheel looks wayyy out of place in your interior.

I got the short shifter back when 360 Dynamics was still operating almost 5 years ago. I have no idea where to get one nowadays.

Stock steering might look out of place, but I would rather have an air bag then smash my face in an aftermarket steering wheel if something goes wrong...

[RoRo]

Seat belts work wonders or better yet a racing harness for those racing seats. I was just adding some constructive criticism. Thanks for the info about the short shifter. I'll keep looking...
Oh yeah, I forgot to ask earlier, what kind of #'s are you putting down with your set-up? Any 1/4 mile times or dyno time?

[Nemasys]

The main reason I left the steering as it is, is for car insurance, taking the air bag out and getting into an accident might make then not cover me. Aftermarket steerings are illegal here and are only allowed on cars that didn't come with a factory air bag system.

Same goes for a racing harness, even tho they are actually better, I know people that got tickets around here for having them.

Back on topic, I have no idea how much power I put down last year. It ran on 6 psi and judging from the way it was pulling I would estimate the power around 160-170 whp. 1st and 2nd gear would just spin out. This year I will try to get on a dyno to see the power if I can. But I will definitely take it to the drag strip and get some 1/4 mile times in!

I'm sorry I don't have an answer for the shifter, I'm sure someone around here knows where to find one! You should ask on Daewootech.