[chris82]

I thought I’d share my build, I’ve been working on it for about 6 months now. A lot of that time spent is waiting on parts to arrive.

I picked the car up for $1250 off an old man.
Grandpa Spec 😂 it even smelt like old man to.

I would have like to picked up an I4 but they’re quite rare over here in Aus, we only got them in 2003. Plenty of V6’s though.

 

[chris82]

I picked up some wheels from FB market place for $220 and gave them a fresh coat of paint

 

[chris82]

I replaced all the shocks and picked up some lowered springs. They weren’t as low as I hoped but they might sag a bit more over time.

 

[chris82]

Time for the exhaust.
I already had some headers to start with so I fitted them and bought a Magnaflow high flow cat 200 cel, 18” resonator and Vibrant 1146
muffler. It’s a 2.5” full system. Not a cheap exhaust by the end of it $1500 aud

It was 90db on idle and about 95db at 4000rpm. Quite loud but when I fitted the turbo and manifold it went down to 80db on idle.

 

[chris82]

Interior is pretty basic.
Seat covers, steering wheel, gear knob, new dash mat, 7” screen and started fitting my boost and wideband gauges
Not a fan of the steering wheel, I have another on the way.

 

[chris82]

Although the car has low kms on the clock, the previous owner didn’t do enough oil changes.
There was heeeeaps of caked up oil in the head and in the sump. The oil pick up was quite caked to. I spent 2 hours with a flat head screwdriver and shop vac digging out the crud in the head. I replaced the lifters as they would have been blocked for sure. The lifters were ticking like a time bomb.
I took the oil pick up off and cleaned that and obviously cleaned the sump out and fitted my oil return for the turbo bung.
Also did the timing belt while at it.
Also replaced the cam chain and drive belts, it runs super smooth now.

 

[chris82]

Fuel pump and fuel pressure reg was next.
I took the back seat out and removed the fuel pump assembly. I installed a Walbro 255 and Aeroflow fuel pressure reg. I adapted it straight to the end of the rail with a rail adapter for an Evo. I just got the appropriate 6an orb fittings.
The fuel pump was pretty straight forward except the walbro is fatter and the plastic surround isn’t big enough. I just used some wire to secure it.
I set the Reg to about 44psi which I believe is stock

 

[chris82]

Getting onto the good stuff now.
Kinugawa TD05H-16g turbo
MMI turbo manifold
Tial 38mm wastegate with 5psi spring
Same side intercooler, i couldnt find the next size up at a reasonable price that would fit. I didn’t need to trim the front bumper at all with this one.
I had to remove some metal to run the intercooler pipes through and ran some rubber strips around the cuts so the pipes don’t rub on metal and wear through.

 

[chris82]

I used a universal 2.5” piping kit and small battery (Full River HC20) this allowed me to not relocate the battery to the boot / trunk. It still starts the car fine and use the original power and ground battery terminals. Time will tell how it holds up. I made up a little battery tray out of aluminium and got a tie down to suit, it’s quite snug.
The pod filter will take the batteries original position.
The intake is a 3” Z / S pipe from Ali Express, worked perfectly 👌 to put the filter right where I wanted it. The filter is a big ProFlow 190mm long. Bit bigger than the average pod filter.

 

[chris82]

The dump pipe is a custom 3” made from the exhaust shop. He charged me $400 but he did a pretty good job, It fits well. He used an 3” exhaust donut to clear the alternator as it’s a tight bend. It also recirculates the wastegate back into the exhaust as its highly illegal here in Aus and a big fine $$$ if u get caught venting exhaust gas to atmosphere not via a cat converter.
I painted it and wrapped it

 

[chris82]

Earlier on I replaced the stock clutch to a Exedy HD stage 1. It’s slightly heavier on the pedal and definitely grabs harder than stock. Hopefully it’ll hold about 200-230hp or so (10psi) I’m not shooting for big power.
I kept the stock flywheel and got it resurfaced and broke the clutch in properly to give it the best chance off not slipping.

 

[chris82]

Very nicely done, I'm sure it's faster just from lightening your wallet.
Congrats.

Ain’t that the truth. Builds like this always cost more than u think. Like double

 

[chris82]

Wow that's some good work there. I used to have one of those Elantras (99 too actually) and it was not bad stock for what it was. I'm sure it'll be fun once that turbo spools up.

Thanks, yeah they’re not a bad little car. I had a different one when I was a bit younger. I drove it all over the place and never missed a beat. Having double the hp should make it fun like u said

 

[chris82]

My 07 Tib has the same evo setup with the exception of it being a automatic… so i have a transmission oil cooler and also a oil cooler with a thermostatic sandwich plate from mishimoto … You going stand-alone or piggy back ?

I’ll be using a Haltech Elite 750 and WB1. The AEM wideband will have to go.
I won’t be installing it myself, I’ll get the shop to do it. They can supply, install and dyno it all. I’m not sure if they’ll go full stand alone or run the haltech along side the stock ecu.
I’ll leave that up to them.

 

[chris82]

Really good build so far! Keep up the good work.

Thanks man, what injector size and duty cycle were u at with urs ? From memory u were at around 12psi ?

 

[chris82]

Awesome content keep us updated i can't wait to see more . I hope that sludge in the oil didn't hurt the bottom end , because these bottom ends can make good power stock long block. What is your power goals?

Thanks man will do. It’s not far from finished.
As for power, 250whp would be nice but we’ll see where 10-12psi pulls it up, I think Aussie Dyno’s read a bit lower than ur dyno’s ( so I’ve read anyway) I want to keep it safe as I really don’t feel like pulling the engine incase it blows up or lifts the head or the clutch starts slipping.

The sludge has been a real pita. When I took the cams out and replaced the lifters I couldn’t get the timing right, took me a few goes which was frustrating.
Some of the sludge i dislodged from the head made its way to the sump. I clocked up about 100kms after I got it back together and had to take the sump off again as it was leaking and there was a heap of sludge sitting in the bottom of the pan. But that gave me the chance to clean it out again. I’ve been worried about it blocking my oil feed but I think I’ve gotten the worse of it.

 

[chris82]

The MagnaFlow High Flow Cat 200 cell.. What’s the Part Number? Did You Buy it off the actual magnaflow site .. Reason I ask because there are to many fakes

I got it from eBay, hope it’s not a fake.
The part number is in the description

Magnaflow 2.5" 200 CPI Metal Core Stainless Steel Cat Catalytic Converter Oval | eBay

MagnaFlow specializes in superior catalytic converter and exhaust technology and has spent the past 30+ years earning its reputation as a global market leader. Magnaflow High Flow Catalytic Converter.

www.ebay.com.au

 

[chris82]

Just installed a catch can and vacuum block while waiting to get my intercooler pipes back from the fabricator. He’s welding on some barb fittings, bov and IACV

For the catch can I tee’d the pcv and and valve cover breather together and they’ll run into the input port on the catch can. The output will run down to the turbo intake so it’ll be always sucking air out of the valve cover (hopefully I’ve got that right)

Rather than having several tee’s in the vacuum lines I decided to go with a vacuum block. The source for the vacuum block is the main vacuum port on the intake manifold.
This will feed out to the bov, boost gauge and Haltech internal map sensor when I get that installed. I’ll just plug it for now.

 

[chris82]

I got all my intercooler pipes back from the fabricator today. I put it all back together and took it for it’s first little rip. Surprisingly it feels quite quick and responsive even on low boost about 5 psi. I did see it hit 8psi for a second there. There’s very little turbo lag. 3000rpm and it’s spooling.
The stock ecu was getting a workout trying to keep the AFR’s within reason. It kept them around 11.5-12.5 on boost. I never gave it 100% throttle tho, maybe about 60-70%.

I also installed a manual boost controller for when it’s time to turn it up a bit.

Now I’ve just got to get some injectors and book it in for a haltech ecu and tune. I’m thinking I’ll go with some Bosch 650cc injectors and aim for 10-12psi.

 

[chris82]

Bit of an update.
I broke / damaged the transmission after doing some pulls and may have launched it a bit too hard. Rather than trying to fix it I picked up a low mileage 2006 Elantra Beta 2 trans. They claim it only has 50,000kms and hopefully it’s stronger. I gave it a bath with some degreaser and pressure wash.

It took me about an hour to drop the trans out and about 5 hours to install the new trans. Had some issues getting the splines lined up and had to swap over mounts. My brother helped me lift it and get it into place. I don’t know how some ppl do it by themselves.


The trans are pretty much identical, I was told I had to get a Beta 2 TOB but mine fit fine. I checked with Hyundai, they are the same part number.
I pulled the TOB off my pressure plate just with a flat head screwdriver. It took about 10 mins just to push the clip down and pop the bearing out. Also re-cleaned the flywheel and pressure plate.

Hopefully I have better luck this time round.

(beta 2 trans on the left)