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GS Forced induction on a GS


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Old June 8th, 2012, 04:18 AM   #1 (permalink)
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Stayer. Turbo kit for 4G69.

Hi people. I can see the interest of the turbo projects. I want to offer to your attention one more project. Its goal, the creation of low-cost, working turbo kit. All that is written in this topic, you can repeat or just buy. I want to remind you that do not understand English, so I write through the electronic translator. I'm not against, if the moderators edit my text. All the formulas and calculations made in the metric system. This project was executed on the stock parts. So don't wait for the giant capacity. However, let's begin.
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Old June 8th, 2012, 04:30 AM   #2 (permalink)
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Many tuners built turbo, then calculated power and etc. However, this is not the right approach. Correctly first, calculate, and then to build the engine. There are a few simple points.
1) Initial settings. (what we have before construction)
2) the Desired result (the one that we want to get)
3) Calculation (we consider the air, fuel, power etc.)
4) Selection of the components (turbine, parts, etc.)
5) Installation (actually Assembly)
6) setup (ECU, pressure, fuel, etc.)
That's it for this scheme will work.
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Old June 8th, 2012, 04:41 AM   #3 (permalink)
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1)Initial settings. So, what we have? Engine code: 4G69
Size: 2.4 L (2378 QC)
Cylinder: 87 mm
Stroke: 100 mm
Power: 160 HP. (117 kW) at 5750 rpm. with 158 ftlbf (215 Nm) at 4000 rpm.
Compression ratio : 9,5
MFI fuel injection,
4 valves per cylinder.
Valves without the hydro-compensators.
Automatic gearbox F4A4B.
For the beginning of these parameters are sufficient.

Last edited by stayer; June 8th, 2012 at 04:56 AM.
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Old June 8th, 2012, 05:09 AM   #4 (permalink)
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Old June 8th, 2012, 05:13 AM   #5 (permalink)
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2) the Desired result.
Oh, this item is always causes a lot of disputes. the voices of the people hundreds of horsepower. But not all people understand that they can use them. You can build any engine. And 400, and 500, and 1000 HP, etc.
However, any increase shall entail significant spending. This relates primarily to the engine itself. Need to strengthen the pistons, rods, gear box, transmission, etc. The total amount of construction is increasing to infinity. Therefore, we must descend from the heavens to the earth and calculate what you can do.
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Old June 8th, 2012, 05:17 AM   #6 (permalink)
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What hp is a gt 6 speed rated up too handle ?
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Old June 8th, 2012, 05:25 AM   #7 (permalink)
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If you leave the stock parts, we can boldly say - 100 HP per liter volume. Go back to step 1. The volume of 2378cc. Thus, the safe capacity will reach 238 hp. A further increase will require strengthening of the engine and the transmission.
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Old June 8th, 2012, 05:57 AM   #8 (permalink)
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However, if the purpose of the project is to leave all part of the stock, then there is another option. This is the performance of the injectors. There are formulas for calculating the performance. They take into account the number of cylinders, pressure fuel pump, duty cycle,the losses of fuel (B.S.F.C.). However, I want to offer another, more simple way.
If the duty cycle is equal to 90%, fuel rail pressure of 3 bar.
The power can be calculated as: the Size of the injector : 5.25 x number of cylinders.
Stock size GS injector = 275 cc.
275 : 5.25 x 4 = 209.5
Thus, the stock injectors, will be able to secure the capacity of 210 HP.
That is, if you take the injectors for example from GT = 305cc. 305 : 5.25 x 4 = 232 HP.

Last edited by stayer; June 8th, 2012 at 06:02 AM.
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Old June 8th, 2012, 06:20 AM   #9 (permalink)
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You think 210 HP is very little? Believe me, it will be a very fast car. Is much faster than a stock GT. Because it is important not only power as such. We must take into account the weight of the vehicle and a gear ratio gearbox. I stopped at the power of 210 HP.
Now you need to make the calculation of the air.
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Old June 8th, 2012, 06:52 AM   #10 (permalink)
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You first need to calculate basic air flow N/A. This is done by the formula.
Basic air flow = V x rpm x 0.5 x E / 1000000
where, V - volume (cc), rpm - (6000) 0.5 - of 0.5 means that the four-stroke engine air in the cylinder comes only at the time of one turnover of the two. E - filling ratio (0.85). The number of 1000000 serves to convert cc to cubic meters.
2378 x 6000 x 0.5 x 0.85 /1000000 = 6.06 m3/min
This is a basic air flow N/A engine. Remember this number.
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Old June 8th, 2012, 07:11 AM   #11 (permalink)
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Now we need to calculate the required pressure. To do this, we use the formula.
Rated power = the initial power x (the boost pressure /atmospheric pressure)
Make an equation.
210 = 160 x ( X / 1 bar)
210 = 160 x X
X = 210 / 160
X = 1.31bar (absolute pressure = atmospheric pressure + boost pressure
For achievement of the power 210 hp need to 0.31 bar (4.5 psi) boost pressure
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Old June 8th, 2012, 07:28 AM   #12 (permalink)
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The next step is the calculation of the air flow with the turbocharged. This is done by the formula
air flow turbo = boost pressure x basic air flow
1.31 x 6.06 = 7.94 m3/min
To convert m3/min to a more correct term kg/min, m3/min should be multiplied by the density of the air at a height of geographic location (sorry, inscriptions in Russian)
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Old June 8th, 2012, 07:38 AM   #13 (permalink)
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Now you can choose a turbocharger. We know the air flow. In the specification of turbochargers is, the parameter of consumption. It is expressed - kg per second. The weight of air per minute / 60 seconds = supply air (It is possible for English it sounds different)
7.94 / 60 = 0.13 kg per second
Now I take the directory and find the desired me turbocharger

Last edited by stayer; June 9th, 2012 at 07:38 PM.
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Old June 8th, 2012, 07:41 AM   #14 (permalink)
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Old June 8th, 2012, 07:45 AM   #15 (permalink)
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This is a very small compressor. This will avoid the lag. It occupies very little space.
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Old June 8th, 2012, 08:01 AM   #16 (permalink)
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There is one more option. Compression ratio. The boost pressure is very low. So no change in the engine does not have to. However, I want to give a formula for the calculation.
the total compression ratio = compression ratio + (boost pressure) in square
9.5 + (0.31x0.31) = 9.6
As you can see, nothing will not need to change.
if you calculates high boost pressure, for example 1.5 bar (21psi)
9.5 + (1.5x1.5) = 11.75
in this case it is necessary to reduce the CR.
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Old June 8th, 2012, 08:09 AM   #17 (permalink)
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So, we have a turbocharger. Now we must make the exhaust manifold. I show how this is done. We will not reinvent the wheel. All is made on the basis of the stock parts. Remove the stock manifold
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Old June 8th, 2012, 08:11 AM   #18 (permalink)
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Stayer you are providing such good info to this site. Please, everyone, e-rep this guy!
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Old June 8th, 2012, 08:15 AM   #19 (permalink)
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Please, everyone, e-rep this guy!
Thank you, I would be very grateful!
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Old June 8th, 2012, 08:22 AM   #20 (permalink)
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In the upper part of the catalysts is the seams. Let's cut off by the edge of the bottom. Remove excess metal inside. If you buy this kit, you will have to repeat it for me.
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Old June 8th, 2012, 08:32 AM   #21 (permalink)
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Now it took me more sophisticated equipment. I make the measurement. Industrial laser makes his case. This is heat-resistant steel 10 mm and 5 mm.
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Old June 8th, 2012, 08:39 AM   #22 (permalink)
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Now I'm clenching part of the machine. And doing welding work. We get this part. Anyone who wants to buy a kit, should welding this part to his manifold
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Old June 8th, 2012, 08:55 AM   #23 (permalink)
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Manufacture welding work. Get a new turbo manifold
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Old June 8th, 2012, 09:01 AM   #24 (permalink)
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Today is all. Now in Russia the holidays. As you have 4 July. After the holidays finish.
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Old June 8th, 2012, 10:00 AM   #25 (permalink)
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Interesting.

Now you only have to pay 1500$ in shipping to get it here.

It's easy to build a turbo system. I am envious, very much, of your seemingly simple access to complicated shop equipment.
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Old June 8th, 2012, 10:14 AM   #26 (permalink)
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I pretty sure he wasn't saying to ship it here. He is showing the most affordable way to get this done with our stock parts.
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Old June 8th, 2012, 10:37 AM   #27 (permalink)
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I cannot wait for this to finish!
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Old June 8th, 2012, 10:38 AM   #28 (permalink)
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I want to say, you can buy it. But you need to apply the welding work.
Option 2. You can do it yourself. Reflash ECU I do or Hackish.
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Old June 8th, 2012, 11:00 AM   #29 (permalink)
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I wonder, do you understand the formula that I wrote above? In fact in 10 times greater. But I am afraid that you will not understand me. This is the main.
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Old June 8th, 2012, 11:25 AM   #30 (permalink)
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Well, for me, I understand your explanation of the formula. To be honest, I'm just really happy you are showing us through pictures how your creating a turbo kit at low-cost.
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Old June 8th, 2012, 11:33 AM   #31 (permalink)
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Hats off to you Stayer.you're one amazing fabricator !!
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Old June 8th, 2012, 11:37 AM   #32 (permalink)
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that manifold looks so OEM its rediculous
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Old June 8th, 2012, 11:37 AM   #33 (permalink)
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I want to say. If you understand the meaning of formula, you can calculate any engine.
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Old June 8th, 2012, 11:38 AM   #34 (permalink)
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for the horsepower you listed is that estimated wheel horsepower or brake horsepower?
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Old June 8th, 2012, 12:19 PM   #35 (permalink)
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according to a friend of mine on Facebook, he says this would be pointless to do to your GS. He says you will not notice the HP gain for all this work you are doing to turbocharge your car. He says if you were to go on a track after applying this build-it-yourself turbo kit procedure, you will be .40 seconds faster than before applying this, which is worthless.

Is this true?
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Old June 8th, 2012, 12:23 PM   #36 (permalink)
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Old June 8th, 2012, 12:38 PM   #37 (permalink)
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why you say that?
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Old June 8th, 2012, 12:41 PM   #38 (permalink)
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why you say that?
because physics say otherwise !!
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Old June 8th, 2012, 01:09 PM   #39 (permalink)
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according to a friend of mine on Facebook, he says this would be pointless to do to your GS. He says you will not notice the HP gain for all this work you are doing to turbocharge your car. He says if you were to go on a track after applying this build-it-yourself turbo kit procedure, you will be .40 seconds faster than before applying this, which is worthless.

Is this true?
if the car goes from 140-150whp to 210whp. you will definately notice it. your friend should stay away from modding cars if he things a turbo will not make a noticeable difference.
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Old June 10th, 2012, 02:03 AM   #40 (permalink)
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CrAnSwIcK is a jewel in the roughCrAnSwIcK is a jewel in the rough
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Originally Posted by akley88 View Post
if the car goes from 140-150whp to 210whp. you will definately notice it. your friend should stay away from modding cars if he things a turbo will not make a noticeable difference.
it is quite noticeable, but yeah it won't shave 2 seconds off your 1/4 mile time...
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