Any upgraded SE turbo with a larger compressor?
Discussion
I'm doing it now and so far everything is smooth. However, the compressor is a 50 trim T04E and the housing is, of course, larger than the stock SE or S4s units. It will just about bolt on fine except for the compressor hits the "heat shield" that is on the back of the engine.
I'm going to try and just bend that shield back to allow for fitment. I've also noticed I'll have to raise the chargecooler 1/2" or so to clear the discharge nozzle.
Has anyone else done this and did they follow the same route? So far the installation hasn't been that hard, just lots of turning bolts 1/8th of a turn at a time.
I'm not doing this on a stock Lotus core turbo so a couple other things are different too, most notably the exhaust flange from the turbine is a little different. But, since I'm making my own exhaust too I don't care about mating up to existing pieces.
>>> Edited by rlearp on Sunday 2nd May 20:37
>>> Edited by rlearp on Sunday 2nd May 21:07
I'm going to try and just bend that shield back to allow for fitment. I've also noticed I'll have to raise the chargecooler 1/2" or so to clear the discharge nozzle.
Has anyone else done this and did they follow the same route? So far the installation hasn't been that hard, just lots of turning bolts 1/8th of a turn at a time.
I'm not doing this on a stock Lotus core turbo so a couple other things are different too, most notably the exhaust flange from the turbine is a little different. But, since I'm making my own exhaust too I don't care about mating up to existing pieces.
>>> Edited by rlearp on Sunday 2nd May 20:37
>>> Edited by rlearp on Sunday 2nd May 21:07
Just an update for those considering doing a larger turbo - it isn't a "quick" job by any means!
I didn't use the Lotus turbo core, instead I just purchased a brand new T04E-50 turbo unit and went that route. This has lead to a number of things having to be fabricated so it definitely isn't a plug and play upgrade.
*Removal of heat shield, fabrication of replacement, stock one fouls compressor
*Fabrication of wastegate capsule bracket, stock one too small on new compressor
*Fabrication of new turbo oil outlet to clear larger compressor and wastegate rod, stock Lotus piece fouled on compressor
*Modication of oil drain return, includes cutting and welding so that it will accept rubber oil hose
*Fabrication of new air inlet hose - stock one way too small for 50 series compressor inlet and WILL NOT expand to suit
*Fabrication of completely new exhaust - flanges of old exhaust don't mate correctly, different type, and at a different height
*Rear of intercooler has to be raised about 1", larger compressor outlet is taller than stock
I've put some pictures here:
www.gt40s.com/images/newturbo/
If you'd like to take a look. I've got to make the exhaust now, a 3" system but that won't take too long since I've done it before with a 2.5". I'll post more and it progresses. Oh, the picture of the two turbos is the stock Lotus SE unit and an identical Saab unit in case you need a core sometime. The Saab unit has a slightly different turbine outlet but is identical in trim and specs. I'm keeping both around until I know this works properly then I'll put them up for sale so that someone can upgrade theirs without trouble.
Ron
>> Edited by rlearp on Monday 17th May 01:42
I didn't use the Lotus turbo core, instead I just purchased a brand new T04E-50 turbo unit and went that route. This has lead to a number of things having to be fabricated so it definitely isn't a plug and play upgrade.
*Removal of heat shield, fabrication of replacement, stock one fouls compressor
*Fabrication of wastegate capsule bracket, stock one too small on new compressor
*Fabrication of new turbo oil outlet to clear larger compressor and wastegate rod, stock Lotus piece fouled on compressor
*Modication of oil drain return, includes cutting and welding so that it will accept rubber oil hose
*Fabrication of new air inlet hose - stock one way too small for 50 series compressor inlet and WILL NOT expand to suit
*Fabrication of completely new exhaust - flanges of old exhaust don't mate correctly, different type, and at a different height
*Rear of intercooler has to be raised about 1", larger compressor outlet is taller than stock
I've put some pictures here:
www.gt40s.com/images/newturbo/
If you'd like to take a look. I've got to make the exhaust now, a 3" system but that won't take too long since I've done it before with a 2.5". I'll post more and it progresses. Oh, the picture of the two turbos is the stock Lotus SE unit and an identical Saab unit in case you need a core sometime. The Saab unit has a slightly different turbine outlet but is identical in trim and specs. I'm keeping both around until I know this works properly then I'll put them up for sale so that someone can upgrade theirs without trouble.
Ron
>> Edited by rlearp on Monday 17th May 01:42
Looks like the turbo I have on my Talon. You will be very happy with it. Maybe a touch more lag, but a whole helluva lot of mid range and top end.
Looks like a lot of extra fabrication for a turbo. Good thing you are capable enough to handle it. If someone with lesser resources was to do this, would you recommend it or no?
Looks like a lot of extra fabrication for a turbo. Good thing you are capable enough to handle it. If someone with lesser resources was to do this, would you recommend it or no?
I suspect it might have a little lag, but you never know. Some swaps I've done resulted in no lag at all, although the naysayers all said it'd be the case. Of course, these were not on a Lotus, this is the first Lotus I've done.
For folks that don't want trouble I'd suggest they just have their stock unit upgraded. Although it limits your turbo choices and performance potential it won't be as much of a hassle.
On the other hand, if you can use a saws all and are patient you can do this swap. Only external help you'll need is an understanding muffler/weld shop to help you make a drain flange, the turbo exhaust flange, and to modify the stock Lotus piping, if you don't have access to a welder. And then of course you'll need to make your exhaust, but you can do this with a saws all, 4 mandrel bent 3" pieces (2 90 degree bends, 2 45 degree bends) and 3" clamps if you don't want to weld. About $85, blood, sweat, time and you'll have as free a flowing as an exhaust as you could want.
Ron
For folks that don't want trouble I'd suggest they just have their stock unit upgraded. Although it limits your turbo choices and performance potential it won't be as much of a hassle.
On the other hand, if you can use a saws all and are patient you can do this swap. Only external help you'll need is an understanding muffler/weld shop to help you make a drain flange, the turbo exhaust flange, and to modify the stock Lotus piping, if you don't have access to a welder. And then of course you'll need to make your exhaust, but you can do this with a saws all, 4 mandrel bent 3" pieces (2 90 degree bends, 2 45 degree bends) and 3" clamps if you don't want to weld. About $85, blood, sweat, time and you'll have as free a flowing as an exhaust as you could want.
Ron
Okay, got everything done and in place. I made the new 3" exhaust too and got that on as well. I've got some new pics up if anyone wants to have a look.
www.gt40s.com/images/newturbo/
Car has a fantastic sound with that tiny little muffler on it, very nice. I am having a little problem though, the car is opening the wastegate at about 0.5bar of boost. So, something is up, don't know what. My thoughts are:
*Switched vacuum/pressure lines to the wastegate with the one on the compressor. But, I'm not sure if this would do it or not.
*My intake hose is collapsing under boost - I had to make one and I don't think it is that great. However, I don't think this would cause the wastegate to open.
*It's a fluke as the car has sat for three weeks and my short drive before it rained was only a few minutes.
*Wastegate capsule is bad.
I'll drive it and check it out. If all gets working I'll drag it over to the dyno to see what kind of power we're making.
Ron
www.gt40s.com/images/newturbo/
Car has a fantastic sound with that tiny little muffler on it, very nice. I am having a little problem though, the car is opening the wastegate at about 0.5bar of boost. So, something is up, don't know what. My thoughts are:
*Switched vacuum/pressure lines to the wastegate with the one on the compressor. But, I'm not sure if this would do it or not.
*My intake hose is collapsing under boost - I had to make one and I don't think it is that great. However, I don't think this would cause the wastegate to open.
*It's a fluke as the car has sat for three weeks and my short drive before it rained was only a few minutes.
*Wastegate capsule is bad.
I'll drive it and check it out. If all gets working I'll drag it over to the dyno to see what kind of power we're making.
Ron
Awesome Ron. Let us know your results. I am interested to see what the 50 trim does for you, as far as performance, spool, etc.
As for your boost problem, a collapsed intake pipe will limit the boost. I know because I had it happen to me on my Talon. Also check for boost leaks, and of course the wastegate capsule, although that is new isn't it?
If you had crossed up your vacuum hoses for the wastegate, 2 things can happen. Unlimited boost or no boost. I don't think crossed up vacuum hoses are your problem, but not a bad thing to check anyway.
Good luck.
Rich
As for your boost problem, a collapsed intake pipe will limit the boost. I know because I had it happen to me on my Talon. Also check for boost leaks, and of course the wastegate capsule, although that is new isn't it?
If you had crossed up your vacuum hoses for the wastegate, 2 things can happen. Unlimited boost or no boost. I don't think crossed up vacuum hoses are your problem, but not a bad thing to check anyway.
Good luck.
Rich
Oh, never posted back on sorting this problem. Turned out the intake hose was collapsing under boost and it was always around 0.5-0.7 bar when it happened. Problem was solved by going to a rubber speciality supply house and getting some 3" hose with special sprial core steel to prevent collapsing. It isn't rubber, some sort of other material good to 275F which is enough on the intake side. Everything is running well now.
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