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..