After doing a lot of research on the DSM forums it seems like a lot of guys were rebuilding and upgrading their own MHI turbos. I thought this was pretty cool and different so i decided to try it myself. I didn't have a Stock frame setup anymore so i started looking for T3 parts that involved MHI turbos.

I found the company many have heard of called Kinugawa. They sell just about every part related to td05/06 in many different configurations. from td05h 16g's all the way up to td06H 25G's. Seeing their website really gave me ideas on what i could do by myself. But the main thing i needed from them was a td05h Turbine housing that has a t3 inlet and 3 inch v band outlet, since i have a Sheepey T3 forward facing hot parts kit, i wanted to make a td05h 20g to fit it.

I have a good friend who buys the rebuild kits for evo turbos from Turbo Lab of america so i started there with the CHRA related part since everything always worked well for him. I decided to go with a TD05/06 Subaru CHRA specifically because the Subaru version has both coolant ports on the L/H side of the CHRA, so running coolant to it, if i decide too, would be easy, if the turbo is facing forward on an evo. Also picked up a their DSM/subaru td05 rebuild kit with upgraded thrust bearings. A 7 blade 20G Compressor wheel (which i believe they get from KTS) and a 9 blade td05H turbine wheel.

Once i got everything, the assembly was really straight forward. Austin from Turbo lab has a really good video on youtube on how to assemble one. I picked up some Brad Penn Engine Assembly lube and worked really well. And if your worried about the assembly being balanced, All the pieces are component balanced and when assembled, should not change. Also if you decide to rebuild your oem td05/06 turbo, and you buy a rebuild kit with upgraded bearings, it WILL NOT fit your CHRA. the new Collar that goes on the inner side of the thrust bearing is bigger and requires a machined CHRA to fit it. Ref the video below for rebuild walk through and it explains the bearings.



well after assembled per the video, the last thing i needed was a Compressor. I didn't want an MHI td06 cover, so i sourced a similar cover but one that was Surged ported, looks almost identical to the FP compressor covers. After reading of guys have surge with 20g turbos and bearing life being threatened by it, i didn't wanna take a chance.
Plus they sound really cool.

Once assembled and mounted on the car, i followed the same method most people do, by priming the turbo, disconnecting the crank position sensor and cranking for about 45 seconds to a minute. first start up was normal, for a awhile i was waiting for it to fly apart
I did however have a FP oil line from OFH. i didn't want oil from the head since i planned on really pushing it o e85.

i put about 150-200 miles on it before really boosting past 5 psi and checking shaft play as much as possible when getting to my destinations. It was a really cool feeling to know i built it and it was holding together really well.

Finally got on the dyno with a little bit of 93 in the tank and 10 gallons of e85 in cans ready to make power.

So a run down of my setup:
Evo 9
Curt Brown 2.0 9.0-1 compression
Curt Brown ported head
GSC S2 cams
Curt Brown ported intake manifold
Curt Brown 65mm TB
ID2000's
Walbro 450
ETS 2.5' short route IC pipes
3.5" ETS intercooler
Grimmspeed 3 port
Sheepey T3 forward facing hot parts

To mine and my tuner's surprise, we managed 457whp and 362wtq on 93 octane at 24 psi! This was on a dyno jet. Checked for shaft play and everything was still perfect! My tuner (Denis @PRL Motorsports) just couldnt believe this little td05h turbine was flowing this much, and on pump gas too. Not only did it make great power but it was holding power all the way 8500rpms!

So we stopped there on pump gas and filled up the tank from the low level light to full with e85.

With E85 it only got better. After working his magic on the computer, we turned it up to 29 PSI and got 538whp and 446wtq. Unbelievable. Not only was this making incredible power for a 20G, but it was something i put together my self. Also beat my expectations by almost 100hp. not bad for piecing together this weird and different setup.
The video below os the 513whp pull at 26 psi.


Pictures below show the 538whp pull. Also the pictures below compare the 20g billet wheel versus a stock evo 16G wheel

 

Dyno sheet and surge cover

 

Its possible to build a IX turbo to 25G?

 

Yes. But would require some machining. The compressor housing will need machined to fit a 25G compressor, and you'll def need a bigger turbine wheel. The stock 9 turbine will choke out before making good power with a 25G

 

But what more do you need? Turbine wheel? the complete CHRA?

The housing you can reuse it right?

 

Things needed:
Rebuild kit
Compressor wheel
Turbine wheel
CHRA machined
Compressor cover machined
Turbine housing machined

 

Your CHRA, compressor and turbine housing can all be reused. Turbine housing may not be able to get machined. If it's cracked on inlet guide vane, a machinist won't touch it