Just go home from work. Spent all day at several exhaust shops about a custom turbo setup. No one is willing to do it. So I'll have to do it myself.
Any ways I have some questions for those who have already installed one or are experienced on theirown/any V6 3.8L mustang. (specifics for plan on bottom if you want to fall asleep)
-WHERE DID YOU PLACE YOUR TURBO? I was thinking where the battery is, and partially cut into the fenderwell. This place seems to have the least amount of wiring and heat sensitive parts.(with the exception of the fuse box.) Regardless I plan to wrap all hot components, and if in this location, use aluminum heat shielding. Also it seems that in this location there will be the least amount of piping, for both hot and cold side.
-HOW DID YOU DEAL WITH THE O2 SENSORS/WHAT DID YOU DO/OR NOT DO WITH THEM?
-This turbo has an internal wastegate 30mm wide. WILL THIS 30MM INTERNAL WASTEGATE BE ENOUGH TO MAINTAIN A 4-5 PISG DESIRED BOOST WITH AND ENGINE THIS LARGE? (Stock wrx's are only 2.0L I believe) It would be too dangerous to go any higher for my car(completely stock engine).
-HOW DO YOU TAKE APART THE STOCK WASTEGATE TO INSERT A DIFFERENT SPRING?
-IF THE TURBO IS WATERCOOLED ASWELL, IS IT POSSIBLE TO IGNORE THIS AND BOLT THE HOLES SHUT AND USE A TURBO TIMER TO COOL IT BEFORE SHUTTING THE CAR OFF? WOULD THE OIL BE EHOUGH?
Thanks for the help!
Car is a 1994 3.8L mustang. Engine and internals are completely stock but came with forged rods from the factory. Head gasket are a metal type.
For the setup I plan to run a single turbo from a subaru wrx(already have the turbocharger) internally wastegated at 12psig . Wayyy to much for me. I wish to change the spring to a softer one which is rated at 4-5psig. If that is not possible then weld it shut and run an external wastegate. Compressor is 50mm and the exhaust side is about the same with a 30mm wastegate. Also a simple bypass valve from the pressured side to between the MAF and the turbo inlet. Then a decent sized intercooler with low restrictive rating.
In addition, fuel upgrades including 30-36lbs injectors, MAF and FMU calibrated accordingly, 255lph pump and Fuel pressure reg.
Most factory turbochargers are sized small for a given engine size. They do this because of the low engine speeds on the street and to make the engine last longer.
Now you take a single turbo that is already small for a Subaru 2.2L, and put it on a larger Mustang 3.8L you are asking for a melt down. Look for a turbo more designed for a Buick GN (Grand National) or call one of the turbo manufactures to size a turbo for you.
Maybe there is a kit already out there?
__________________
Tony Berger
91 LX 337 Incon Twin Turbo
D&D Viper T-56 6 speed
Maximum Motorsports front to rear
94 Cobra
99 Lightning
and it's JUST-N-LX
It's funny you mention that because I race with a grand national driver. He is also an employee at our local dyno shop Shelly Performance of the Spokane,WA area. His stock turbo is slightly smaller, about 46mm with a similar sized wastegate. This turbo is the same on the Subaru sti rated at 19psig, and a 2.5L engine I believe. I have checked the flow requirements and this turbo is large enough.
But I think you are right about the wastegate. I'll just weld it shut and run a larger 35-50mm external.
With an FMU would I really need larger injectors and MAF if I calibrate it to a 10:1 AFR over the stock 11:1 with the 19lbs inj.'s? I am only going to run about 4psig.
Sorry I meant fuel pressure over stock, my mind went on a complete tangent 'cause I was doing two posts at once. What I meant to ask, was: Is it "safe enough" to run my stock fuel system (19lbs/hour) and MAF, with a 255lph high pressure pump, with an FMU recalibrated to 10:1 or 12:1? Turbo psi will be 5 or less.
There is some sort of formula to figure out proper injector sizes. I don't have it though. Let me do a little searching. I will try to get back to you tomorrow night.
Finally someone who can actually help me. Everyone else is just telling me what I already know. I think because I have only a few posts they think I'm just another kid or something. Most of them tell me the wrong info, and then I have to correct them. (Not to gloat or anything)
Any ways I saw that calculator somewhere online aswell, and I have it in one of my mustang performance books, but for the life of me I can't find it. I just moved two weeks ago. I think I remember that up to 250hp the 19's were fine. But that was their limit. And that if there were any further plans, it was just a better idea to go slightly larger than your injectors hp range. I know that on the 5.0's the injectors were 19's, and they made at least 215 to the wheels.
My car maybe runs 110 to the wheels , and at only 4psig I might make 140 . So I think it'll be okay. I am not going to recalibrate my FMU. I'll keep it at a slightly rich, but safe 12:1 psi over stock 40. When I race I am 3g's and up, and I don't want to lean out up there. I'd rather have $hitty gas mileage instead of extreme wear and tear. My plans are to get this done, and when it is really needed, rebuild and forge. Then I already have the ability to increase the pressure with only a little more funding on an engine which can handle it better. Maybe 300 to the wheels!(Hopeful thinking) I'll start looking online aswell.
Trust me, going too rich like 10 to 1 the car is just going to flutter, pop and bang. If you are concerned about it that much run closer to 11.5 to 1... Even that is really rich. Dumping a lot of fuel in there isn't really going to make it any safer. There are a lot of people out there that will tell you different, but I have been doing a lot of reading on this stuff lately.
I'm still not sure. But the calculator really helped out alot. It prettymuch said that my 19's were okay.
The FMU is from a Procharger Kit I bought on ebay, and it is rated at 12:1. I'm not sure what those kits run at, but most run at 8-10 psi. Maybe I'll drop it down to 10/8:1, but I'll try the 12 first. But thinking about it:
Stock Fuel psi: 40
Rate: 12 psi increase/1lbs of boost from FMU
Boost desired: 4-5
Calculation: 12(5)+40=100psi Fuel Pressure at full boost.
Maybe that is too much.
I'll go ahead and buy the kit that has all of them. That way when I am at the track I can put a higher calibration, and while on the street and generally out boost, a lower one.
I was talking to my friend today who has a vortech supercharger on is 87'(maybe 86) 5.0 with MAF conversion, 30lbs injectors, 255lph pump, and calibrated MAF. His FMU is set at 6:1 and he is detonating at WOT. I know that with larger injectors, you can drop a level or more on your FMU, but he did that and is still having problems. I told him to use his original FMU calibration, 12:1 and get back to me. We'll see.
Oh I'm sorry. I didn't realise you were talking about the ratio for the FMU... I was talking about the air fuel ratio. I little mix up there. I'm really not sure what ratio you would use on the FMU.
I was reading into your post more... You'll want to water cool the turbo.
Finally someone who can actually help me. Everyone else is just telling me what I already know. I think because I have only a few posts they think I'm just another kid or something. Most of them tell me the wrong info, and then I have to correct them. (Not to gloat or anything)
Insult the people here trying to help, nice, real nice :thumbsup I checked your other posts and nobody was thinking anything about you. They where just trying to help.
Good luck with your project, I hope it turns out the way you want it too. (no, that's not sarcasm. I mean it.)
__________________
Tony Berger
91 LX 337 Incon Twin Turbo
D&D Viper T-56 6 speed
Maximum Motorsports front to rear
94 Cobra
99 Lightning
and it's JUST-N-LX
Thanks, but I am not trying to insult anybody. Maybe it was taken the wrong way or whatever , but they're just words on a computer anyway, don't take it soo personally. And the Help IS appreciated, and I understand that they are just trying to help, but it gets annoying when I am given the wrong suggestion over and over again, and I f-up my car. I wont give any advice if I am not 100% sure. I just want it from somebody who is legit. Again, to anyone reading, don't take it personally, the same happens on other forums and I tell them the same(keep it real), and I hope that others will tell me when I am full of it, because I am not afraid to be wrong, and love to learn.
Any ways, we took some time on my friend's car today(the 87'), and tried the 12:1 and it was wayy to rich, but only at WOT. However he has 30lbs, with a larger pump and we determined that to be the main cause (duh). My other friend with an 89' let him borrow his 6:1 and 10:1 and they both helped drastically at WOT. But I am sure it would have rum better it it didn't have bad rings and burning oil. Gonna try his kit when the turbo is hooked up, to find the best one.
After reading my post, I guess it does sound bad, and my second one in response to that sounds even worse.
Oh well, thats how I talk/type.I guess I'll just keep it to myself. But like I said don't take it personally, or directly.
Back to work: I forgot about the water cooled part. I took apart the water pipes, and they kind of just run in and out in a small spot, less than an inch. They don't even wrap around the impeller. Looks like this:
-----< Water
l
O V Impeller
l
----->Water
I would imagine that it would run really hot anyways, but the stock setting is 12psig on a 19psig capable turbo. I am only running 4-5. I think the oil should be enough. I hope, cause I really don't want to run the lines.
-WHERE DID YOU PLACE YOUR TURBO? the battery side is fine............your hot side will be out away from where the battery was anyways.........
HOW DID YOU DEAL WITH THE O2 SENSORS/WHAT DID YOU DO/OR NOT DO WITH THEM? don't do anything with em, leave them in, they will still adjust your timing and fuel to the added air coming into the engine
WILL THIS 30MM INTERNAL WASTEGATE BE ENOUGH TO MAINTAIN A 4-5 PISG DESIRED BOOST WITH AND ENGINE THIS LARGE? kind of hard to answer this one without knowing exactly what turbo it is..........19g, 16g etc..........
HOW DO YOU TAKE APART THE STOCK WASTEGATE TO INSERT A DIFFERENT SPRING? same as the above, you need to try to let us know a little more about the tubo.......well atleast me, i think simple
IF THE TURBO IS WATERCOOLED ASWELL, IS IT POSSIBLE TO IGNORE THIS AND BOLT THE HOLES SHUT AND USE A TURBO TIMER TO COOL IT BEFORE SHUTTING THE CAR OFF? WOULD THE OIL BE EHOUGH? the oil will be enough to keep it cool, but generally speaking, the oil helps cool the shaft and the water helps cool the bearings, with that said, i would look at running both. If you don't plan on doing alot of racing, then go with the oil for now. The turbo timer really wont work for what you are wanting it to do.........i installed a turbotimer in my twinturbo'd car and it works fairly well, but it really only needs to be used when the turbo has been used hard........this will prevent coking inside your oil gallies.......it is a good investment in a way, but if you take a couple minutes and just sit in the car, let it idle for a few minutes.....it will do the same thing, saves ya some cash that way too...........
the rest of your thread, you pretty much have the answer for..........myself, i would do the build just a bit different and use a different turbo set up, but it is your car and you already have the turbo...........so just take your time, keep asking questions and you will git r dun..............there is nothing like a turbo'd motor..........freakin awesome
hotwheels of turborides
__________________
my cars:
1992 mustang gt twinturbo'd
1988 mustang gt bottlefed
2004 mach 1 collecting dust
1989 mustang coupe 4cyl.
1980 mustang coupe 4cyl.
Insanemustangs.com
Need turbo help!!! 
. Wayyy to much for me. I wish to change the spring to a softer one which is rated at 4-5psig. If that is not possible then weld it shut and run an external wastegate. Compressor is 50mm and the exhaust side is about the same with a 30mm wastegate. Also a simple bypass valve from the pressured side to between the MAF and the turbo inlet. Then a decent sized intercooler with low restrictive rating. 
Everyone else is just telling me what I already know. I think because I have only a few posts they think I'm just another kid or something. Most of them tell me the wrong info, and then I have to correct them. (Not to gloat or anything)
, but they're just words on a computer anyway, don't take it soo personally. And the Help IS appreciated, and I understand that they are just trying to help, but it gets annoying when I am given the wrong suggestion over and over again, and I f-up my car. I wont give any advice if I am not 100% sure. I just want it from somebody who is legit. Again, to anyone reading, don't take it personally, the same happens on other forums and I tell them the same(keep it real), and I hope that others will tell me when I am full of it, because I am not afraid to be wrong, and love to learn.
