First well talk about the manifolds. My buddy and I had very little welding experience but it help for 2 years by some sort of miracle. I chose to make log style manifolds for this project due to the limited space. The materials used were 1 3/4 and 2 inch aluminized pipe. Also a set of stock manifold flanges. We used a hole saw and a drill press to make the holes in the 2 inch pipe. These took a lot of time with trial and error fitment. Once done I heat wrapped em up tight.
Last edited by twinturboGTO; 02-14-2010 at 02:08 AM.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
I chose to mount the turbos up front to eliminate lag and for the simple fact that it looks nasty there. This posed some fitment problems with the hood as well as some heat concerns with vital components. But after some adjustments to the manifolds it tucked under nicely. Only problem is there is no room for a filter. So I just run screens.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
Then the tial wastegates were added to the manifold with a wastegate dump leading back into the exhaust. Don't cheap out here they are worth every penny. Also don't run open dumps or it could mess with the wideband giving you or your tuner problems.
Next is the intercooler and charge piping. I bought them both from CX racing on ebay. All of it cost less than 300 bucks and has worked perfectly for me. Make sure your couplers are quality 4 ply silicone. Also use t-bolt clamps not hose clamps.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
The 5 mph crash bar was removed for the installation of the intercooler and I made custom brackets. The charge piping can be tricky. However I bought a bunch of bends and just cut to fit exactly how I wanted it. Piping consists of 2 1/2 inch into the intercooler and 3 inch out. After the intercooler I used a HKS SSQV blow off valve. It is a good choice for low boost apps and is self adjusting. Plus it is the meanest sounding BOV imo.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
The boost controller was by far the hardest component to install. It took a while to find an ecu pin out but after that it was cake. One thing to note here... I hardly used this at all. Now that I have the 8.5 psi wastegate springs and a stock motor I find the boost controller useless. Its pretty much useless on low boost apps anyway. It can be more useful on high boost apps where you can vary boost by gear for launches and such. It does look trick though haha.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
Also installed was a boost gauge and wideband. Both very east to install. A good wideband is absolutely necessary when running a turbo set up. I use the Innovate XD-16. It has saved me a few times from going lean when i would play around with boost settings. Don't risk it!!
Now to the fuel set up. You dont have to go as crazy as I did but I have plans to forge this motor so I wanted the fuel system to be ready. It can handle about 800 to 1,000 hp. I used an aeromotive A-1000 pump. Its noisy as hell but it has never let me down. I also used aeromotive for fuel pressure regulator,rails and filter. Just remember the FPR has to have 1:1 boost ratio. I also upgraded to mototron 60lb injectors and 8 AN braided SS line. I used my factory fuel line as my return (the LS2s have a dead head system).
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
Here is some other random things that also had to be done. Gauges installed in dash pod. My battery had to be moved to the trunk to make room up front. SInce I do run this car at the track this lead to me installing a battery kill switch. I didn't want to drill into the back of my car so I hid it behind my tail light. The only thing is I have to remove my tail light to race. I also decided to paint up my battery box to clean it up.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
I will have some more pics coming soon as I have added some turbo blankets and reinstalled the engine covers. Im also having the design copied in stainless steel since finally after 2 years a manifold cracked.
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
cost break down
Custom down pipes and manifolds $200 (we made them ourselves)
Turbos were $500 total!!.. I got a Great deal they were taken apart and checked by a turbo shop. They were shortly on a viper but they decided to go in a different direction so I picked em up cheap.
Fuel rails were $50 on ebay
Injectors were intalled but not used so i got em for $400
FPR was $125 on ebay
A- 1000 pump was $400
wideband was $300 got a deal on this.
intercooler was 180 on ebay (air intake temps were only 90 degrees on the dyno and it was 80 in there so its legit)
Charge piping with couples was 180$ (ebay)
Fuel fitting prolly about $150
Glow shift boost gauge only 30$
oil filter sandwich plate and mis. fittings and hoses for oil drain and fuel line $200
tial wastegates $400
Blow off valve $180
other little crap prolly like $400
2005 GTO twin turbo, Red Int, Custom Twin Turbo, Tial 38mm wastegates, HKS blow-off valve, Snow Stage 2 Methanol Injection, Aeromotive A 1000 pump, Aeromotive FPR, Professional Products fuel rails, 60lb mototrons, custom turbo manifolds, Spec 3+ clutch, gmm rip shift, Tune by me on HP tuners
Hell of a job. Wish I had the nuts and wallet to do this.
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