Building a G16b - Turbocharged + ITBs

[binz]

A few months ago, Sanjay and me were exploring options of what could be done to Baleno engine, on a budget without fancy big name parts. Since its a daily drive, nitrous was immediately out of the equation. Had a couple of turbos lying around but having driven the car turbocharged for over 25,000km, 180bhp just didn't seem exciting anymore. For those of you who don't know, Sanjay is the man behind Wolf's honda city (Race Dynamics: Honda City VTEC), the 13 second automatic accord as well as infamous 800hp Supra. His builds are always special, and this one will be no different. Going the Turbo route but with individual throttle bodies.

Work started last week and here's where its come:

[Racedynamics]

Making a plenum for the itbs is a task in itself. To reach the target volume, we needed to use a 4 inch id stainless steel tube. With not much space between the intake ports and the firewall the master cylinder has to be relocated to accommodate the new plenum. In the future we may go with a dual plenum.. But not anytime soon. Itbs are 43mm

Fabrication begins:



Runners are positioned, aligned and tack welded.



All done !


The plumbing has been removed and sent to be Tig welded.

Meanwhile the Engine has been removed too and is being built from the ground up.

[james]

Im glued to this thread! Knowing you and Sanjay, this is going to be one killer build!

I wish you'll all the best!!

Cheers!!

[killjoy]

All the best, hope it comes out well. I know Ron Chinoy of RDD was also mentioning that he wants to do a ITB Honda Turbo project....

[binz]

So things have come to the point of no return. The blocked has been pulled out to be machined. The stock conrods are being replaced by forged steel rods.


Head removed


Block removed


Stock rods vs forged






The set:

[paras211]

looks like you guys are going all the way. Its been so long since a new build is being logged on tbhp. Feels like the good old days. Some more details about the turbo and intercooler choices and reasons, I am saving up for boosting my car so need to know what to buy.

[pganapathy]

Oh wow. Now glued to this thread. Am awaiting more information and photos on the complete build. Wanna do something similar but with my esteem

[rjstyles69]

In a long time,an awesome build coming up one helluva thread binz and sanjay . I am glued to this thread and good luck with the build.

Originally Posted by paras211

looks like you guys are going all the way. Its been so long since a new build is being logged on tbhp. Feels like the good old days.

I concur.

[binz]

Originally Posted by paras211

looks like you guys are going all the way. Its been so long since a new build is being logged on tbhp. Feels like the good old days. Some more details about the turbo and intercooler choices and reasons, I am saving up for boosting my car so need to know what to buy.

Since you've asked, the turbo is a Mitsubishi TD05h 16g, using it since i had it on hand. Its on the smaller side and will be upgraded once the bottom end is sorted out.

My intercooler is yet to come, have mounted a slightly larger(15%) one for the plumbing mockup. Will be changed by the end of the week

Originally Posted by pganapathy

Oh wow. Now glued to this thread. Am awaiting more information and photos on the complete build. Wanna do something similar but with my esteem

Go for it. The stock engine on the esteem can handle a lot! Even on a budget, you can pull out a lot of power. What info do you need?

Originally Posted by rjstyles69

In a long time,an awesome build coming up one helluva thread binz and sanjay . I am glued to this thread and good luck with the build.

Thanks!, will catch up when its done.

[binz]

Installed bonnet dampers on the car earlier. Around 3000 rupees landed in india from Taiwan. Shipping took about a week and got through customs without any issues. You can buy them here.


Comes as a set of 2 - Look at the pic in the previous post

[cityvic]

Binz,seeing your older threads and builds I can surely vouch and say,this is another crazy build coming up.
Please post some more pictures of the car.

Thanks
Rohin

[kutlee]

is the bonnet going to vibrate? I was thinking engine torque damper would be useful.

[binz]

Originally Posted by kutlee

is the bonnet going to vibrate? I was thinking engine torque damper would be useful.

That was purely cosmetic! It will be useful but needs to be fabricated. The bolt on omp strutbrace with the engine damper is out of production.

[revtech]

It just seems to get better..forum really needs more threads like this good luck with the build i have no doubt its gonna turn out exactly the way you want it to be

[binz]

A whole bunch of parts came in today via Borderlinx. Bringing parts down has never been simpler with them. No hassles of customs, no delays being a dhl service and very economical shipping costs.



Most of these things have been bought for the sake of reliability - oil,water lines and metal gaskets for the turbo, t-bolt clamps and silicon hoses to keep things together under boost.



Being an itb setup, having a steady vaccuum supply is essential for the car and brakes to run right. That's what the vacuum manifold below is for. Along with the silicon vaccuum tubes we don't have to worry about leaks or hoses coming loose.







The injectors also came in - more on that later