engine head cover and breather

engine breather play an important part for high reving RPM..and i made two suitable side for the outlet port..it's located at the blue union fitting as in picture above..actually i don't really preffered there but it is most suitable as it underneath cover filtered engine oil from draining out

here is another angle where the head cover is not yet in proper finish..the union or AN fitting are being attached in another welded fitting..as the fitting made from aluminum i sent all this thing to welding shop coz it requires special equipment..

modification on my oil catch tank..a hole to fit filter in

oil catch tank mounting used to attach in my engine bay..well grab what ever i saw and found this bracket..belasah jer laaaa...


this are the union AN fitting assembly..it has a reverse thread to fit in with reinforced hosess..the thread also has 60 degree pitch angle an its not as same as normal thread in market or hardware

aiya..how to fit another albow fitting..? hmmm lets do magic...

here is the special tool i used to fit the hose and fitting together..without it..all useless bebb....

and get 11/16" wrench size to tighten it up

TADAAAA...magic


engine head cover after painting an also i attached with transparent plastic ignition cable cover..WHERE DO I GET THIS..? haha..HOME MADE BEB...


but since the cover is not really suitable to me than i change it with original plug cover..sprayed....look nicer ..and u can see the complete of oil catch tank and breather line fitting...

making of intercooler piping

what u are looking is a complete finished of my intercooler piping cluding intake filter with 6" K &N plus adapter to fits in 609 airflow sensor


here i used 3" pipping with silicon reducer hosess from airflow sensor 4" to 3" and 3" to 2.5" to fit turbo bellmouth


and abg yen welded a 1.5" pipe for blow off valve

reducer silicon hoses from 2" to 2.5" to fit between intercooler and intake magnifold piping

pic b4 fabricating of BOV pipe

after abg yen fabricate the adapter to fit turbo outlet port then i make a divergent shape by cutting and welding..cool huh... pipes used are 2" and 1.5"

then i used an elbow 2" 45 degree silicon hose to join in those piping from turbo to intercooler..and u can see there is an outlet port for wastegate vacum pressure

bahan2 nyer adalah....

port for BOV

stainless steel ready made elbow..i bought this at sg besi hardware..

this an adapter 2.5" to fit with throttle body..abg yen sent this thing to mechineshop and customized it..thanks bro...


on final assembly i decided to cut the adapter and attached with throttle body..this is to make the piping more movables during installation and ease of maintenance

cutom intake magnifold

standard GSR intake magnifold with throttlebody..kotor laa...

here is the base for custom intake..can see the injector port at alluminum plate n it gonna be sandwiched with gasket and stainless steel plate..this is a prototype which is not proper of fabrication n design..there is also a harden alluminum crank pulley which self made by lay mechine..it is not an aftermarket item which available in any performance shop..it's about 1/3 lighter than original pulley..

the alluminum plate was milled by abg Yen in accordance to original intake measurement.

stainless steel tube been cut to meet the magnifold shape and walded using arc walding mechine..


and this what does it look like when complete...

haaha...then i spayed with zichromac primer..before put color on it..this is to make the colour stick on it..as we know that difficult to spray stainless steel..where did i get this..heheee

pic after sprayed with colour..opsss..forgot to weld with vacum port, throttle cable n coil plug braket...it's only has a braket for injector..aiyaaa..takde hal..sendili bikin chaa...

here we can see how the attachment of alluminum and stainless steel..there is a gasket in a middle and i also put a glue on it...before that i required to cut inside the holes for better air flow..

haaa..vacum and servo brake port including all braket welded...

siap jugak beb...

turbo TDO5 reassembled

parts of turbo ready to reassembled


ensure all parts cleaned including toolsfrom here we can see the turbine housing has been ported to larger area including entry port where the air circulate to prevent airflow through sharp edges..

i coated all parts with their name for references...compressor housing also has been ported to make smooth airflow in the circulating area..i had used a very special tool to do it due to very confined space to get into the area..it was my own hand...hehe..actually used a doctor scissor..becouse it can clamp up a sand paper while sanding..there also a new key way lock to put or rotate the compressor housing in other direction

this is a picture after installation of the compressor wheel...

ready to install to my engine....

turbo TDO5 servicing

here is my turbo TDO5 VR4rs..it is a secondhand item..got it from somebody in PJ with rm 500..looks very dirty and for sure oil leak found around the housing.. it does't look good to install in my engine..


now after cleaning i dismantled the turbo to see if any thing broken, defect or sign of damage..

remember to mark on area of compressor and turbine wheel position so i can reinstall it back without balancing..even though this is not a proper way to do it but at least it can minimize the danger of failer..100,000 rotation of wheel in a minute will caused a disaster if without balanced..

compressor housing after cleaning..but still looks dirty...n on right pic is 16G centrifugal compressor wheel..twin blade..u can measure the inducer and exducer 1.89 inch n 2.68 inch..

here is the repair kit for this turbo..its contained with 2 journal bearings 1 thrust bearing, piston ring clip, oil seal, O-ring and gasket

journal bearing replaced n u can see piston ring clip (located behind the turbine)is also renewed, this is to prevent an oil leak through the turbine wheel..compressor has sand blasted and polished then it looks nice n shining..

porting the inlet and outlet of turbine housing make it larger area but it difficult to polish caused of harden materials

here is before and during porting of turbine inlet port..all of this work was not be carried out at any workshop...i made my self at my working place during my free time..hehe save cos maaaa..