Costs of my build

Costs and ongoing details of my build as well as new modifications.... Scroll down to see the latest.

Before detailing these costs, I'd like to mention that my build up costs are a bit excessive. Why? Because I felt like I needed to spend the money up front for a motor that would handle a bit of abuse in the event that I had problems during tuning. A more reasonable cost motor can be built to a spec providing easily over 180 hp. I can talk more about a budget turbo motor later. I disclose my costs because I see so many write ups on the internet that look great, but don't detail exactly how cost effective those projects were.

New design and costs

I spoke with Tim Jenkins at DOA Racing based on personal recommendations. Decisions and pricing:

• 22RE new casting (not 22RTE) as it has more "meat" in the head area. $1450
  • .5mm over exhaust valves - stallite
  • 1mm over intake valves - ferria
  • Hand ported and bench flowed by Tim.
  • Cam TBD based on flow results. New rocker assembly.
• JE 8.0:1 94mm bore "turbo" forged pistions - LC Enginering. $600
• Severe duty rods: magnafluxed, shot peened, polished, $135
• DOA Racing high pressure oil pump (shimmed bypass) - $150
• 22RTE high volume oil pump (replacement for the DOA unit, dunno if I actually need this, guess due to rocker/cam issues) - 22re.com - $133.99
• ARP studs $115
• Late model 22RE manifold + fuel rail, $145
• Steedspeed.com Custom Fabricated Top mount 22RE turbo manifold, setup for 38mm wastegate, Leen - Master CNC machinist $450
  
• Steedspeed.com Custom blow off valve BOV04-200 $CALL
  
• Ceramic coating of manifold $160
  
  
• 1987.5-1988 turbo - (195500-1370) PURPLE TOP saturating 550cc/min, high-impedance, square plug, side tab, side tab (M3k supra turbo also works at 440cc)88 | 13b T | high | square | offset | 550cc | purple | 195500-1370 $100
• M3k supra 7GMTE turbo also works at 440cc injectors $65
• Injector Connectors for RX7 T2, $20 ebay / Standard Motor Produces #S696 $19/each or use NAPA 800-9213 and shave the ridge off the injector.
• Injector cleaning / service (http://www.witchhunter.com)-new pintle caps / o-rings - $60 (all 4 w/shipping)
• Earls 12mm x 1.25mm to 6AN or use a 12mm Banjo bolt (check your engine, I've seen 10mm and 12mm both x 1.25) $12
• Misc AN fittings and braded hose $50
• Remote filter setup (used for turbo) - large capacity, fed by 6AN, output 4AN to turbo $50
• More braded line, AN fittings, $90
• Cooler plugs, recommended by LC Engineering for engines boosting over 10psi, NGK R5672A-8, stock 7173, $2.50/ea
• Accel Ferro-spiral spark plug wires, 8mm, pn 7954R (R=red), custom fit, $35.00
• Mr. Gasket 6018 wire loom setup, gotta hold the wires off the turbo, trust me on this. $35
• Forced Performance FP4ANFilter 4AN 10 micron inline oil filter for turbo $100 (after I ate a turbo due to new motor "debris"
• 60mm 7MGE throttle body, adapter gaskets $50
• Misc Metric Hardware - stainless hex replacement bolts, etc $100
• Engine machine work - turn crank, bore, hone, deck, surface flywheel, $480
• Replacment engine bearings, timing chain, steel guides, $160
• Balance rotating assembly $200
• Intake pipe (steel / alum) - enough to do multiple intakes $80
  
  
• Turbo #1 Initial "break-in" turbo is a Garrett t3/t04b in V-trim. Not a high boost turbo. We'll use this for inital tuning befor going to a higher tech Garrett ball bearing unit. $160 (ebay)
• Cost of rebuilding said turbo.. It's bearing is trash after 200 miles, probably due to metal shavings in a failed valvetrain - $375
  • Bullseye Power t3/t04b with 4-bolt DSM flange, 8/2004
  • Oversize internal wastegate
  • Supports 350hp
  • .63AR turbine housing, ceramic coated black.
  • Polished compressor, inlet 2.75", outlet 2"
  • -4AN oil inlet / restrictor
  
  
  
  
• Cost of rebuilding said turbo (again) and upgrading to a 360 thrust bearing. I believe the failure was caused by high EGTs (too little timing). $230 + 3 hours time - turbo ended up being trashed due to bad center section. HEAT IS BAD.
• Turbo #2 Cost of replacing said turbo with a t3-60, .48 exhaust, 360 thrust, clipped exhaust wheel, .60 AR compressor, 360 thrust, externally gated $575 shipped - gpopshop
  • Garrett T3 turbo
  • Rebuilt by gpop shop
  • Supports 300-350hp
  • .48AR turbine housing, clipped turbine for more flow.
  • .60AR compressor
  • 360 thrust bearing
  • I think this failed due to oil starvation caused by a a clogged in-line filter
  
  
• Turbo #3 - Garrett .60/.63 $450
  • Large in-line oil filter, using a stock 22RE oil filter $120
  • Failed for unknown reason (everything looked OK) - returned for repair, I invalidated the warranty by oepning it. It has some rear turbine bearing wear, but not a lot. I suspect this was a bad turbo.
  
  
• Turbo #4 - Garrett/Nissan Ball bearing turbo from R33 Skyline $200
  • Ball bearing / water cooled
  • .64AR, Nissan Skyline R33 GT25-T
  • IDs: BNR32: 14411-06U00 (Nismo)
  • BCNR33: 14411-24U10 (N1)
  • BNR34: 14411-AA401 (N1)
  • So I actually destroyed this thing while trying to rotate the housing. It was partially rusted and I impacted the exhaust turbine on the housing while rotating it. It's not rebuildable.. I would have really liked to try this turbo
  
  
• Turbo #5 - currently installed - Bullseye Power
  • T04B48 - Bullseye power
  • About $500 on sale.
  • 300hp at 12psi
  • Oil cooled.
  • .55AR housing
  • Borg Warner unit, 54.15mm inducer, 67.5mm compressor
  • turbine is 73.4 inducer / 64mm exducer, Stage 5/P trim turbine wheel.
  • Stainless exhaust housing and polished compressor.. It's pretty.
  • Probably a bit bigger than I want, but it was a good price, comes with a warranty, and it might be ok in 48 trim. We'll see. I can't use my water cooled setup on the CHRA.
  • Well, it's beautiful, if nothing else. It puts a mean pull into the 4runner, but it creates that pull pretty late in the game. You can literally hear it start to spool, but due to the pass of the turbine, it spools slowly. 6-7 psi at 3500RPM, 10-12 at 4000 RPM. Great peak power, not that great for lower RPM grunt. Very efficient, cool intake charge.
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• Upgraded fuel pump - 255lph Walbro - $110 (not currently in use, stock seems to be working fine for current power level)
• Engine powder coating - $150
• Misc silicone hoses, reduces, air filter, turbo plumbing $170
• Relocated knock sensor
• Megasquirt-I V3 PCB, assembled $330
• GM IAT sensor $20
• Wiring harness for above (build yourself for a lot less) $53
• Hays Super-Brute Clutch Kit #90-400 $150 (ordered for a 22RE, instead of 22RTE, DOH!) 22RTE 236mm clutch/pp - same as 5M -GE and 7MGE supra, 22RE = 224 clutch/pp
• T43HDMM ACT Clutch (heavy duty pressure plate, modified street disc) - $350
• LC-1 Wideband 02 $190
• LC-1 Wideband 02 sensor replacement, after running about 8 gallons of 100LL $75
• TIAL 38mm wastegate .4 bar spring (6psi) - got a deal - $100
• Basic bleed type boost controller - $60
• Marine fuse block (allows me to do some electrical expansion) $35

Ongoing Modifications, problems, and changes:

7/28/07 Blew out a "paper" intake manifold gasket at 12-15psi. I hadn't correctly retorqued my intake manifold since I built the motor, I was starting to weep water. I retorqued, but too late.. Blew a big leak on the way to work. I ordered a solid plastic replacement gasket - one of those "heat insulating" deals on ebay. I don't buy the insulation deal, but I do buy that it is a solid gasket that isn't going to be impacted by coolant. I considered replacing the 440cc injectors while I was in there, but decided I was too lazy.

8/1/07 Megatune says I'm hitting 100% duty cycle during low gear acceleration. This indcates I'm probably hitting over 200hp, but isn't going to work.

8/7/07 Spent several hours rerouting the 22RE heater hoses. In particular, the hose that wraps around the rear of the head ends up too close to my downpipe. I had insulated it, but felt it might cause a long term reliability problem and potentially leave me stranded some day. I took the stock pipe, cut it up, ended up welding it into a U bend from teh bottom of the manifold and placed the water feed on the passengers side of the intake manifold. Down side is that the hose is in the way of the heater control, something else to deal with.. One step forward, half step back.

Still to-do.. Need to figure out how to do an intercooler, results from other 22RE turbos running intercoolers are very encouraging (100+ degree drops) - no real room to do it with my bumper though.. Considering alternatives.

Head and Cam specifics

22RE head by DOA Racing - new Top Line casting

• 218cfm @ .425/16" water 103 F
• 200cfm @ .425/16" water 106 F
• 418/428
• 216/226 @50
• btc/2 --- abc/32
• bbc/47 --- atc/-3
• +1mm
• Closed pressure @1.595 120/open @450 240
• 3 angle valve job: cut 60/45/30 faced @45