FTO GS 4G93 turbo build

So you want a hairdryer on your FTO? Or do you already have a hairdryer in it? This is the section for it. All other big power projects & forced induction goes here too.

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mongoose_dog
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FTO GS 4G93 turbo build

Post by mongoose_dog »

As some of you might know from faceballs and my annoying questions, this is an ongoing turbo project.
I'm a long time lurker here, and this is the first one that was worthy of posting about.

Car is a '95 FTO GS, originally with a 4 speed auto box, imported from Japan in 2004. Was around 58k then, now is 133k.
Came with 17 inch Advan AVS Model 5 rims, and a stainless steel backbox. Otherwise fully stock. 1 lady owner (not kidding, there was a kid seat in the back with some snacks on the floor).
IMG_20150904_125349.jpg
Being a poor student, I've added some polibushes, strut bar, and a subwoofer.
Years passed, had a family, boring diesel estate, but the FTO stayed and I decided to do what I always wanted - turbo it.

Brake disks needed change, so I upgraded from single to twin pot fronts. Got a bigger master cylinder as well - 15/16, but didn't like it, so now it's running an Evo 4 one with 1'.
Lowered the car with Apex springs, and I'm surprised how well it handles now - stiffer and lower, but still damps good.
Next thing was the manual conversion, mainly because the 4 speed auto gears were not enough - 1st and 2nd had a huge gap, and 3rd was already close to 1:1 ratio.
Polibushed the engine/gearbox support beam to stiffen it up a bit for the incoming turbo.

It starts like this:
00.jpg
Oil pan out for oil drain:
14.jpg
Impreza WRX TD04 to go in, since it's should suffice for 1.8l engine that wants low-mid rpm boost:
16.jpg
That later was found to be very hard to place where we wanted, so it was ditched in favour of the bigger better one - TD05 from an Evo IV.
act02.jpg
Intercooler in and painted black:
21.jpg
Intercooler piping done:
22.jpg
Turbo manifold version 1 - design based on ToxicFab's Evo VIII manifold:
28.jpg
Unfortunately, this would come too close to the hood/bonnet, and even with insulation would fry the paint, so it was dropped.
Shorter one was made:
33.jpg
Painted black and insulated:

37.jpg
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Re: FTO GS 4G93 turbo build

Post by mongoose_dog »

It is now running a TD05 Evo IV turbo on stock 0.8 bar, DET3 piggyback ECU, 440 cc injectors from Impreza STI, standard fuel pump and lines, Xenum 10w40 oil, stock compression of 9,5:1. Custom exhaust manifold, Bosch BOV, custom piping, still has the cat.
f.jpg
So far it has only been road tuned - clutch smells under boost in 1st and 2nd, perhaps 3rd, but it's not slipping in 4th and 5th. I'll need to change that before dyno, but I'd like to leave the clutch as the weak link in the setup and save the gearbox, diff and driveshafts.

I've no idea what it makes, but it kept up with a Mk 7 Golf GTI from 120 to 200 km/h, and it puts a huge smile on my face.
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spetz
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Re: FTO GS 4G93 turbo build

Post by spetz »

Really nice work there, nice to see a 4G93 SOHC get some love in an FTO
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Re: FTO GS 4G93 turbo build

Post by bjk »

Hey hey. Good to see a thread and nice work on the conversion. The 4 pot would be good for weight distribution for sure.
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Re: FTO GS 4G93 turbo build

Post by Technikhaus »

Nice work!
That'd be a fun car to drive!
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Re: FTO GS 4G93 turbo build

Post by dstocks »

Now thats a conversion I havent seen before. Great job :D .
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    Re: FTO GS 4G93 turbo build

    Post by silverGPX »

    Good work, need to clean that engine bay though


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    mongoose_dog
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    Re: FTO GS 4G93 turbo build

    Post by mongoose_dog »

    Technikhaus wrote:Nice work!
    That'd be a fun car to drive!

    it is indeed fun to drive, but I need to sort out the clutch.

    silverGPX wrote:Good work, need to clean that engine bay though


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    yup, 2 years with almost no driving will do that.
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    dazjb
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    Re: FTO GS 4G93 turbo build

    Post by dazjb »

    Nice work! You planning on getting it on a dyno? ... be interested to see what it's kicking out.
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    Re: FTO GS 4G93 turbo build

    Post by mongoose_dog »

    dazjb wrote:Nice work! You planning on getting it on a dyno? ... be interested to see what it's kicking out.

    yes, once I decat it, and put a new exhaust system. maybe a clutch.
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    Re: FTO GS 4G93 turbo build

    Post by Supplanter »

    LED ALL the things.
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    Re: FTO GS 4G93 turbo build

    Post by mongoose_dog »

    Supplanter wrote:
    quite.
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    Re: FTO GS 4G93 turbo build

    Post by bjk »

    Took me so long to realise this referred to your username haha.
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    Re: FTO GS 4G93 turbo build

    Post by mongoose_dog »

    so, couple of days ago a friend of mine invited me to a dyno day, and I thought why not.
    2 BMWs, 2 VW Corrados, 1 FTO (what the hell is that), and 1 VW Golf GTI Mk7

    BMWs were both stock, automatic and diesel; one of the Corrados had ABF cams, and the other had a G60 supercharger; the Golf had 13k kms done to it, and stock as it gets.

    the whiny Corrado was a very close match for numbers, but had instant torque from 1500 rpm, and linear power delivery until the very top, so I reckon it will have me.

    the GTI though.. factory data says it's 220bhp, 350Nm - it measured 264bhp, and 417Nm.

    I was pleasantly surprised when my FTO didn't blow off the welds on the intake and made decent power.
    expected somewhere around 190bhp, but got about 205bhp (153 in aus powerdoos) and 277Nm.
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    dyno result
    dyno result
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    spetz
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    Re: FTO GS 4G93 turbo build

    Post by spetz »

    Nice results. Power seems about perfect for a mix of performance, reliability and ease of driving
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    Daniel2019
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    Re: FTO GS 4G93 turbo build

    Post by Daniel2019 »

    Hahahaha reliability and ease of driving :lol: :lol: :lol: Soft!

    But yeah that is a good result, well done.
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    Re: FTO GS 4G93 turbo build

    Post by mongoose_dog »

    yeah, I need reliability, since it's my only toy, and the diesel family estate is boring.
    should see some development next year though.
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    Re: FTO GS 4G93 turbo build

    Post by bjk »

    Where are the videooosss. :lol:
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    Re: FTO GS 4G93 turbo build

    Post by Rob Furniss »

    Nice build and great result, well done.
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    Re: FTO GS 4G93 turbo build

    Post by silverGPX »

    Why get a diesel estate then?


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