OK, So I thought I would start my own thread to document the progress and results of my project.

Be advised!!! Patience will be required as this is a low budget project and dealing with unforseen issues will always slow things down... :eek:

A little background:

I've been looking into this an doing a lot of research for about year and a half and by now I have a pretty solid idea of what I want to do.

About the car: 2008 Yaris TS with 23K miles on the clock. Body of a Yaris and soul of an xD :P

If you are not familiar with the TS, here is some specs:

Euro version Yaris T-Sport
5 door
17" OE Wheels
Upgraded suspension (Although I'm currently running on Tein Basics)
Trac Control / VSC / ABS / 4 wheels disc brakes
Engine 2ZR-FE 1.8L diual VVT-I
Short ratio C56 5spd tranny

The engine bay is the same as in the xD... same layout same dimensions... same everything.

Here is the car:

http://i445.photobucket.com/albums/qq175/castrex/Droppedandclean002.jpg

http://i445.photobucket.com/albums/qq175/castrex/Droppedandclean014.jpg

About the project:

Low boost turbo set up.

My goal is to get this done with quality parts for less than $2.5k inlcuding engine management and tuning.

Currently I have 85% of the parts that I would need and about $1400 spent.

As this is all experimental and the results are pretty much unknown i will be doing this on 2 stages.


First stage:

I will be using a GT2554R ball bearing garret turbo. Because I found it almost new by dirty cheap.
This turbo should be good for up to 200whp altough on my initial set up and according to my calculations I'm shooting for 175whp with the 0.5 bar (7psi) spring.

I will be using a 38mm Tial WG and the internal turbo WG will be deleted.

A CX Racing FM intercooler (27x7x2.5) with 2.5" pipes. Ijust got a Universal set of pipes from CXR and will work from that.

For the Blowoff I picked a Bosch diverter valve. I'm planning to have it re-circulated but will see...

As for the manifold I will be using a Log style manifold... BTW I just picked today and looks great!! It was not cheap as it end it costing about $350 but is all SS and will hold a lot of punishment plus it will flow enough for much higher boost in the future.
I will be taking a few pics of the mani tonight.

I still need to find some one to take care of the dowpipe as that one will be one tricky part. Hopefully a competent exaust shop can do it.

The turbo will be semi lower mounted to the manifold... there is just enough space back there to acomodate.

Just to make sure the turbo won't ever touch the fire wall I will instal a TRD dog bone to limit the engine back and forward movement. Has any one noted how bad this engine swings? :eek:


Now for the Fuel and management:

Stock fuel system with larger (2AZ) injectors. The 370CC injectors from the 2AZ are good for 200whp so I should be OK.

For management I picked an AEM FIC. It will have to be hard wired and it the tuning will certantly be a challenge. I friend will help me with that part of the project.

For safety I picked a AEM wideband and will probably get a pyrometer also.


A few pictures of the goodies!

http://i445.photobucket.com/albums/qq175/castrex/TSturbokit003.jpg

http://i445.photobucket.com/albums/qq175/castrex/TSturbokit001.jpg



http://i445.photobucket.com/albums/qq175/castrex/TSturbokit002.jpg

http://i445.photobucket.com/albums/qq175/castrex/TSintercooler.jpg

Subscribed.

I'm guessing with your budget, you plan to do all of the installation work yourself?

About the plans for a STAGE 2:

This will only depend on the success of the stage 1 but if my car survives, this is what will come short afterwards:

-Upgrade turbo to a GT28RS ( Disco Potato )

-AEM Water/meth injection

-LSD + clutch

- 10-11 psi of boost

.... and hopefully around 225whp


Stage 2 would set me another $2.5k ouch! but if everything goes well it should be worth it.

The LSD and a Disco Potato are NOT cheap!

Subscribed.

I'm guessing with your budget, you plan to do all of the installation work yourself?

I will install the easy stuff... intercooler, manifold, turbo, downpipe etc...

The FIC will be wired by a friend (I'm an electrically challenged)... he is an AEM tuner and it should cost about $600 for the instalation and dyno tuning.

For the intercooler piping I will look for some Air con shop. They are usually good cutting and welding alum pipes.

looking good Castrex! Get us pics of that manifold ASAP!

interested to see how this turns out

sounds like your already way ahead of the turbo toyotas project, heh. do you know if your going to place the MAF sensor before or after the turbo? i think someone was already talking about this in another thread.

if yours is euro sport.. do they offer some euro cars like a corolla sportivo? :icon_biggrin: haha
but back to the topic. any ideas as to when you will have all parts and begin to installing it? and resources to where you get your parts will be appreciated. im saving up if this works =]

Pictures of the manifold..!!!

The welder did a pretty good job concidering this is his first manifold.

I gave him all the parts and some drawings and this is what it came out:

http://i445.photobucket.com/albums/qq175/castrex/TSturbokit011.jpg

http://i445.photobucket.com/albums/qq175/castrex/TSturbokit015.jpg

http://i445.photobucket.com/albums/qq175/castrex/TSturbokit013.jpg

http://i445.photobucket.com/albums/qq175/castrex/TSturbokit012.jpg

Will be keeping an eye on this :)... good luck with the setup

Thats actually not a bad looking manifold, especially if it really was your welder's first. I can't wait to see how all of it fits together and to see how big of a PITA the tuning is...

Like Chang asked, you're doing a blow-thru MAF set-up aren't you?

sounds like your already way ahead of the turbo toyotas project, heh. do you know if your going to place the MAF sensor before or after the turbo? i think someone was already talking about this in another thread.

The MAF is going before the turbo for sure. A MAF after the turbo only means more problems when tuning....

The piping routing and MAF position should be very similar to Guillo's (puerto rican turbo xD) set up.

I'm really not inventing anything here! I'm going for what has been already some what proven...
The manifold is very similar to what TurboToyotas used for their turbo 1NZ's. The down pipe will be similar to theirs as well. After all the manifold/engine position and exhaust line up for the 2ZR is very similar to the 1NZ cars...



if yours is euro sport.. do they offer some euro cars like a corolla sportivo? :icon_biggrin: haha
but back to the topic. any ideas as to when you will have all parts and begin to installing it? and resources to where you get your parts will be appreciated. im saving up if this works =]

Europe gets the best sport compacts! no question about it... those guys are crazy for the small hatchbacks...
They had the Corolla sportivo with the 2ZZ engine, now they have the Auris 180 (180hp turbo diesel engine), the new Ford Focus turbo is seting the standard now for high HP FWD cars... The meganes, clios, 207's, so many TRUE hot hatches...

I won't give any estimates as regarding when will I have this done... As i said this is a budget project and dealing with unfoseen events is to be expected...

For example right now I don't even have my car and I will get it back in aboout 2 weeks... I snaped one of the shifter cables (... yeah I know!) and the delaer didn't had the spare in stock so thhey had to order it from Japan. After I get it back it will go to the paint shop for a front bumber paint job as some dude from my work scratched the bumper on the parking lot...

Then, my friend the tuner is really busy and will help me when he has time so that could set me back some time.

All in all, the project is rolling and I have almost everything that I need... but I won't rush anything... This is a hobby after all and it's to be enjoyed in all the stages... Is not only about going fast... is about take some pride in the hard work you've done!

And where do I get my parts? every where! from friends, at the classified section of this forum and yarisworld, ebay... is just a matter of patience... you have to be looking for the bargains.

I got the turbo for $400 (is $800 new), a new 38mm tial for $160 ( retails about $250), new Bosch diverter for $25 (retails for about $60), CXR intercooler and piping is only about $150 on ebay. The manifold can be had from JGS presicion. You can get a stage 2 and only weld the radius plate and turbo flange.

You also don't really need an external WG as all the GT25/28 turbos come with internal WG's. Is just that I found the tial for cheap that that gives me some extra adjustability.

The FIC I got from $150 on the forum, injectors for $50 on the forum as well...

Just keep your eyes open.

Thats actually not a bad looking manifold, especially if it really was your welder's first. I can't wait to see how all of it fits together and to see how big of a PITA the tuning is...



Thanks!

Since the manifold is not visible, we don't really need to worry for the looks.. is all about functionality... soft edges and transitions for a good flow.
With this kind of manifold you will never have to worry about cracks... this is steam pipe gauge ss pipe. It will last more than the car.

I will ceramic coat it as well as the down pipe... so they will look mate gray when their finished.






Please feel free to ask what ever you want or give suggestions! nothing is set on stone.

Subscribed* :)

Awesome Castrex and congrats on starting your project...I wish mine would have gotten finished and now i've gone a different direction with my car...The only thing I have left out of my stuff is the 370cc tC injectors and powder coated pipes...I wish you all the best and can't wait to watch this journey...

iahhh dialoo brutal i like it!!!! :gun:

hehe it definately doesnt look pretty but it definately looks strong to do the job :P

watching

hehe it definately doesnt look pretty but it definately looks strong to do the job :P


What you are talikng about!!! It's beautiful...!!!! :icon_smile:

J/k

The simpler the better...

People always look down at log style manifolds but it has been proven that you can actually get better response with a log style mani and they usually only fall short at the top end on HIGH horse power cars...

For less than 400 hp a Log style gets the job done :shock:

Is it just me or is the turbo flanged angled a little too far out?

Is it just me or is the turbo flanged angled a little too far out?

Too low? or to far to the left?


The turbo flanger is at the left so the downpipe bend is easier to do... and the turbo will be lower mounted...

Too low? or to far to the left?


The turbo flanger is at the left so the downpipe bend is easier to do... and the turbo will be lower mounted...


I was thinking that you might have issues with the turbo hitting the firewall with it being at the angle that its at...

I was expecting closer to a 90 degree angle when looking at it from the side...
have you had a chance to test fit?

I was thinking that you might have issues with the turbo hitting the firewall with it being at the angle that its at...

I was expecting closer to a 90 degree angle when looking at it from the side...
have you had a chance to test fit?

I haven't done the test fitting yet. I just got down there and took some measurements.

The key here is the turbo size... I can see problems with that angle if using a t3/t4 turbo but the GT25R is fairly compact.

Will see how it goes in a couple of weeks when I got my car back and running. I will have to install the turbo and manifold in order to make the dowpipe... and start working with the rest of the piping.

Oh, I had a different question too, the Dog Bone that you got, which engine mount does it replace?

Oh, I had a different question too, the Dog Bone that you got, which engine mount does it replace?


Can't really explain the exact location but just get below your car and you will easily find it... This isn't really an engine mount... as it doesn't support any engine weight. This bone limits the engine back and forward swing.

This is suppose to be much better than a regular engine torque damper.

C-one has one of these but theirs is a urethane piece and from what I've heard is not suitable for a DD as it will transmit a lot if vibrationto the chasis.

This TRD piece is supposed to be some where in between the OE bone and the COne urethane bone.

Can't wait to install it.

I got it from microimageonline.com

Found a picture over at kamispeed. Dog bone aka roller stopper

It links the tranny to the frame:

http://www.kamispeed.com/product-p/br.s141014bc-ac.htm

youll notice the dog bone pretty easy when you change your oil, its right behind the drain plug from what i remember.

one of a kind lol.

Hmm, I'm not sure by your little comment there but if your trying to be a d^ck, go back to the tC forums...

one of a kind lol.

Hmm, I'm not sure by your little comment there but if your trying to be a d^ck, go back to the tC forums...

easternsanc -0 YELOSUB - 1 :icon_mrgreen:

Thanks for the free bump!


The shifter cable arrived from Japan today. I should have the car back from the dealer on Wednesday.

Right fater that is going to the body shop to some scratches fixed and the front bumper painted... and then to keep up with the turbo project!


Yeah, I know is going slower than I would like to.... but at the end the wait will only make me appreciate the hard work even more!

I've been putting money on my other car (a coupe AE86) since the Yaris was on the dealer.... so that doesn't help my budget either!


On the other hand... the corolla is running strong!! :love:

I gots a question. you say you gots a euro spec. dont they have a turbo kit or supercharger in the europe world for your car? lol

Nope! nada... zero support.

Although it is an Euro car, there are not that many of them in the streets.... so I guess TRD is not interested....


There is a Swiss company that created a supercharger, putting out 215hp. But the price tag is over $10K

with that money. I would just get a celica gt4 lol. goodluck wif the project:icon_smile:

OK, as I don't have any real updates and won't probably have any in a few weeks, I thought I could write down a list of the parts that I'm using for my project in case any one is interested


-Turbo: Garret Ball Bearing GT2554R This unit should be good for just above 200 whp... Very quick spooling unit.
on my turbo I had the internal waste gate deleted to use a external unit. But there is really no need to do this.

- Intercooler: 27x 7 x 2.5 cooler from CX racing with one of their 2.5' universal pipes kit

- Blow Off Valve: Bosch diverter

- Wasgate: Tial 38mm with a 0.5bar spring. (You don't need this if you use an internally gated turbo)

- Engine Management: AEM FIC

- Manifold: 1zz-fe stage 2 manifold from JGS performance. You can get the radius plate and turbo flanger from them as well.

- Downpipe: custom made ( haven't done it yet )

- Injectors: 2AZ-FE OE injetors. 370cc ( should be good for around 200whp)

Guages:
- Wide band: AEM UEGO
- Boost: AEM vac/boost mechanical gauge


turbo Oil and water lines: will be custom made.

And that's about it!! Pretty simple as you can see...


I will also ceramic coat the manifold, dowpipe and turbo hot side.



Also will be looking into an Oil cooler, but after I have the turbo working properly...

^^Can't wait...Jealous over here...Makes me sad to wonder what could have been with mine :(

Makes me sad to wonder what could have been with mine :(

Alright YeloSub, we get it. You tried it with TT, it didn't work. We know it didn't work, because at least once a day on some thread on ScionLife you let everyone know about it multiple times.

Cut it out man. Instead of pitying what experience you had, try encouraging the experience of someone else.

Alright YeloSub, we get it. You tried it with TT, it didn't work. We know it didn't work, because at least once a day on some thread on ScionLife you let everyone know about it multiple times.

Cut it out man. Instead of pitying what experience you had, try encouraging the experience of someone else.

Don't lecture me, your not my father, I already have one of those...I have been a member far longer than you and have always been willing to help members here on SL...Ask around...If you had read my posts, most of them were in response to people complaining about forking over 2k for r&d for a turbo and I was making valid points...

Am I still ____ed that I have a box of unsold turbo sh^t sitting in my garage? Yes...I can vent when I want and don't need your permission, thanks...And I don't feel I said anyhting wrong in my post...I have been PM'ing Castrex and anyone else who has had questions...So if I poke fun every once in awhile about my turbo mishap and it helps me feel better, so be it...

Now, back on topic and good luck Castrex...

I have been a member far longer than you
Wow dude, so you're that douchebag. How long you've been a member at this forum or any other has no meaning. Why would that even have to be brought up?

If you had read my posts, most of them were in response to people complaining about forking over 2k for r&d for a turbo and I was making valid points...
Yes, I know, and my complaint was not about that. Nor did I say that you were being unhelpful. 98% of your posts are constructive.


Am I still ____ed that I have a box of unsold turbo sh^t sitting in my garage?
[QUOTE=YELOSUB;3303676]So if I poke fun every once in awhile about my turbo mishap and it helps me feel better, so be it...]

Yes, you got screwed, even after SEVERAL people on this forum warned you that indeed, Todd will screw you. And its a little more than poking fun, you're polluting every thread about boosting or modding with posts about what happened with TT. All I ask is that you stop. Poking fun and whining are two totally separate things.


I wasn't lecturing you the first time, man. Trying not to this time. All I ask is to stop polluting every thread with this crap about TT. Yes you had a bad experience, yes it sucked, yes you were wronged. We all understand by now.

If you wanna talk smack, PM me...If not, STFU and let this back on topic...

Interesting project.. cant wait till its done.. I wonder how fast that weightless car can go with 200 whp.

as for the lil argument above, yelosub is just making a plain comment.. i dont see why someone should make a bid deal about it.. Obviously you dont have an idea what he has gone through with his failed setup, sharing thoughts is fine here but not to attack someone elses post unecessarily.. If the OP has no problem with his post, i dont see you would have problems with it. Its the one polluting the thread.

yea I would be more blown then yelosub if that happened to me. I wouldnt stop B****in about it lol. I would of also just kept savin up and let a shop finish the job but thats just me as am I r questioning myself daily how big can 200whp can effect a light car. but im down to get a turbo kit once they come out with one

Castrex, any updates?

Castrex, any updates?


No updates guys Sorry!!

Everything on hold for a couple more weeks... I had to dump some money to fix my other car (AE86) and that unexpectedly took away from my budget...

It's so frustrating... be so close and so far at the same time :?

No updates guys Sorry!!

Everything on hold for a couple more weeks... I had to dump some money to fix my other car (AE86) and that unexpectedly took away from my budget...

It's so frustrating... be so close and so far at the same time :?

lol i know what you mean...
so close... yet. so far..

wow. Props. Good luck!

Just found this thread, im a little late i know, but I'm glad to see you turbo-ing the yaris castrex! It's great that you're taking the time to document it on the xD forums as well :)

anyway, one thing i noticed while reading through the thread; it was mentioned that you have a euro spec 4 door, and xDkidd asked if there were any turbo models already sold there, wasn't there a Vitz RS sold there? I know the RS was sold with a 2zr, and wasn't there a turbo option?

anyway, I'm excited to see how it works out; in for updates and learning

No turbo model available here. The only one would be the Turbo Modellista Yaris which is a 1.5L Turbo RS and is only available in Japan to the best of my knowledge.

My car is a Euro Yaris TS... is basically the JDM RS trim with the 1.8 2ZR engine.

Interesting, I could have sworn they had the turbo available for the Euro too; but you are correct, I was indeed thinking about the Modellista turbo. oh well; where are you located? I was always under the impression you were in the states haha

Keep us updated with the project, sounds cool as H___!!!!

Should I start calling u Dynatek Cas? ;P hurry up guy! lol

[quote=TRDxD;3353609 where are you located? I was always under the impression you were in the states haha[/quote]

I'm from the sunny and rainy Costa Rica, Central America :wink:

Should I start calling u Dynatek Cas? ;P hurry up guy! lol

Shut up dude!!! I'm no pulling no Dynateks on you guys...!

No one is more anxious about this than I.

Is just that I had some problems and money has been tight...:icon_frown:

I lost the Yaris for almost 4 weeks when I popped a shifter cable and the dealer had to backorder it from japan. During that time I had to pull out my project AE86 that had sitting on the garage and dump a bunch of money to get it up and running to daily drive...

And since I started working on the Corolla I got a little carried away (that car is awesome) and did a suspension and brakes upgrade to get it ready for an event I had last weekend with a local AE86 club.

Some proofs for you to witness that I'm not a sissy DRIVING my cars.. :P

Took 1st place out 15 corollas on a race track event..

That's me on the blue coupe leading the bunch:
http://i445.photobucket.com/albums/qq175/castrex/3er_interclubes2009_1574.jpg

http://i445.photobucket.com/albums/qq175/castrex/3er_interclubes2009_1590.jpg

http://i445.photobucket.com/albums/qq175/castrex/INter%20clubes%20Nov01%202009/Hachiinterclubes076.jpg


And 2 weeks ago with the Yaris at the same track... Just having fun at an open track day.
me on the Black 1.8L TS. My Brother driving the 1st gen Red TS (his is a TRD Turbo 1.5L 14owhp)

Here is a video http://www.youtube.com/watch?v=UutdU0y4k6U

The car held great... I did 3 lap sessions 20 minutes each. Stock brakes and Tein basics susp.

cool yo.

haha was jk buddy

nice job with the hachi :)

Any new news? Hope things are going well...

any updates?

in for updates

CASTREX, what happened to the project?

nice work:bow:

can someone just contact m2 and see what they can do?

The elusive forced xD. A TRD was promised on launch several years ago, but never materialized. Countless others have started down the road and have failed. There is NO KNOWN xD bolt on forced induction product in existence.

The mechanics are achievable, but once you get to the ECU - good luck fella. Try to remap the computer - you'll become famous if you can do it yourself without MAJOR involvement from Toyota engineers.

The elusive forced xD. A TRD was promised on launch several years ago, but never materialized. Countless others have started down the road and have failed. There is NO KNOWN xD bolt on forced induction product in existence.

The mechanics are achievable, but once you get to the ECU - good luck fella. Try to remap the computer - you'll become famous if you can do it yourself without MAJOR involvement from Toyota engineers.
program air/fuel mixes? You're just nay saying with no back up. What makes you think this different than any other car?

Man, read slim99's recent posts...He's just full of inspiration and positive comments...

no known xd bolt on? ahhahahah i had no idea

That ebay turbo kit looks very tempting haha jk

Nice man, wish you the best, not trying to thread jack here but if you get a chance you should check out a friends turbo Yaris here in CA:
http://www.microimageonline.com/forums/showthread.php/19-Garm-s-turbo-project , not the same engine, but still awesome.....

What we need is a turbo kit. Maybe get the. Other cars wif the same engine involved like the vibe nd get a company to make us sumtin

its the vibe corolla xd and matrix right? any others?

its the vibe corolla xd and matrix right? any others? just the us spec ones. Yaris has them but in europe and so on .. ptuning wld do it if they get 10 ppl in wif a 2k deposit. But we'll see what happens after a visit to je performance by one of our members. If sum1 can contact m2 maybe they can do something. They said they wld after sema but idk what happened