My turbo build, from scratch. Two new prototype Kseries topmount manifold designs!!!

[Ctd-fab]

Hey Guys

Ive been fabricating a custom built high performance turbo setup specifically for the EP3 chassis and its getting close to completion so i thought it should have its own thread.

I'm sure all of us familiar with k series turbo setups know how much a pain run of the mill side mounts can be. First off you have to relocate everything and its mother away from the mass of hot pipes now running right behind the valve cover. Then you have to deal with heat issues from the down pipe that's usually running right by the brake master not to mention having a dump tube snake around everything. And last but not least is problems with the actual turbo location. Some companies even decide to angle the turbo past the recommended 15 degrees maximum for the center section. This can lead to excessive smoking out of the down pipe and possibly even lead to premature bearing failure.

I designed this manifold with complete consideration of all these issues and problems. The first one was built off of a TSX with the help of LoCash, however sadly enough his manifold never reached a fully completed stage. Fast forward to now and after tweaking the manifold a bit more and playing with gate locations its almost ready to breathe some k20a3 fire. One issue withTSXs/ Ep3's and I'm assuming Rsx's is the room or lack thereof to even install such a large piece of metal from the bottom without unbolting a bunch of stuff and dropping the subframe. I had to get a bit creative....

The CTD K series T3 Top mount was born, dubbed affectionately "The Special K"



Here is a pic of turbo placement on a K24 in a TSX. 35R T3 open, 3" downpipe. This engine bay is quite a bit cleaner than mine so I'll put these pix up first, haha.





57 Trim, nice little 400 hp setup



Not yet ported 100%, flange also needs to be machined















Little more progress on intercooling this beast.

So I like options, that's why I will be designing this kit with both a Water to Air Intercooler and a normal Air to Air front mount. I ordered a nice little 500HP core from Bell Intercoolers and started brainstorming.



After discussing with our in house engineer about end tank design we decided to go a bit more in depth so he CAD modeled the core with tanks and did a complete CFD Analysis. This is the start of the design process to fabricate the best end tanks possible to utilize the core to its fullest potential.





I hope to have a downpipe tacked together tonight, clearance looks to be the same as a TSX chassis, full 3" with room to spare. I have kpro and a walbro ready to be installed.


Any comments or suggestions are much appreciated. Thanks for reading guys and this is my personal car so i plan on making the very best kit I can. This is also my first full K build so if you have any helpful tips please feel free to share.:up::up:

[Ctd-fab]

I am still currently working on the other top mount design. I will say that it is a fully divided long runner manifold designed only to work with a certain OEM true Twinscroll turbo. It is similar to some of the new bigger Borg Warner EFR turbos that are also divided yet internally waste gated. This lets the you have a true twinscroll setup yet not have to worry about the hassles of buying and installing two wastegates and dumptubes.

These manifolds will be dyno'd back to back

[FoReVaPmP]

Hope it all works out for you..... I would like to see the fitment in an EP3 and not a TSX tho ....

[AUTiger]

glad to see you posted over here. I can't wait to see what these manifolds do. Do you still have the a3 or have you swapped too?

[Ctd-fab]

glad to see you posted over here. I can't wait to see what these manifolds do. Do you still have the a3 or have you swapped too?

Ep3 love :) Been awhile since ive been on here, the backwards posting is kind of hard to get used to.

I still have the bone stock K20A3 and I hope to push it to around 350 on both setups. If anything happens to go wrong I also have a backup JDM K20A waiting. Everyone undervalues the A3, I want to see what it can do. N/A I have pushed the Ultra-Lean tuning envelope with over 25:1 afrs light cruising and 18.5:1 high speed cruising. Vtec-E FTW!

[Ctd-fab]

I plan on this kit being the most complete kit available for the EP3 chassis with every option.

Pre-turbo water meth
Water to air intercooler
Air to Air intercooler
Intake with stock battery
Cold air intake with small battery
TurboSmart 40-45mm WG
Tial 38-44 WG
Open dump, recirc dump
3" Hood exit upside-downpipe
3" downpipe
Tial 50mm BOV
Banjo turbo drain
Weld on turbo drain

Its nice being the guy that actually makes the stuff. Endless possibilities

Thought you guys might like to see a 700+ HP setup looks like...

[jeenyusss]

its always nice to see a kit come out that doesnt skip steps to save a couple bucks (such as when revhard kits were getting shipped with ebay blow off valves and ebay wastegates.)


good luck to you and your endevors, keep it updates, very nice work.

[gtimportfanatic]

i like this!

[Ctd-fab]

Treadstone IC and ID1000's on order!!!

Thanks for the info monjarassi, thats exactly the one I was looking at!

From the pix I saw of the old Full Race topmount I'm glad I never had to build one when I worked there, haha. The primary size and runner geometry is quite a bit different, placement looks to be close. My manifold much more compact and has better wastegate location for chassis fitment. I don't believe their manifold fit in ep/rsx's.

[Ctd-fab]

The second car with the blue valve cover is my Ep3. I really should have pressure washed it before starting this project, haha.

Fitment is guaranteed on any K series in any chassis except the FA/FG

[ep3jd]

This is super cool

[monjarassi]

So who will sell this mani?

[Ctd-fab]

This is super cool

Thanks!

So who will sell this mani?

Pm'd



More progress...

I fit the teardrop wastegate and I am very pleased with the location. Currently I'm using a TurboSmart Comp 40mm gate but a Tial 44 should fit also no probem. The dumptube is very simple, a 7 inch long straight! Less welds, no bends, less cost to the consumer and higher reliability. It also looks like offering a Recir dump tube will be a possibility. The mock up return line also worked out very well and has quite a bit of room to spare around the hot stuff. This will be taken to the local fitting supply store to be made all one piece. I have mocked up the return using a "No weld" banjo fitting but will also have an option for a weld/tap on bung. Who doesn't like options right???




Since my Ep is bone stock and has all the stock lines in place I would like to show you how this setup clears everything. One of my main goals in this project is to minimize relocation of anything.




So....the JDM Fairy showed up last night

I have always wanted an up-pipe car so I threw one together. I happen to have a large sack of pre-cut 3" 15 degree pie cuts left over from my "JDM Bender Bot" sculpture. My hood already had a dent in the front so I thought adding a hole in the top wouldn't be so bad. I do plan on making a regular 3" downpipe soon but you gotta have a little fun sometime right?









I should be starting her up by the end of the week!!!

[Ctd-fab]

[Ctd-fab]

Hey guys, thought I would post up some new pix. It runs and drives on a basemap right now, I wanted to get some data on normal cruising IAT's with with and without a cold air intake for the turbo. Still working on it little by little and trying to stay ontop of other peoples projects as well.

The Up-pipe


How the turbo sits in the car. Not much room back there so it looks huge! haha



I took some video just cruising around so you guys can hear how loud the open hood exit is, its really not bad at all. I'm probably going to tune with a regular downpipe to get better data.