SKY888

Hi Guys,

I'm sorry, I know I don't have a Lancer EVO. I used to have an EVO 3 (w/ GT3076r) back in the Philippines. It produced around 500whp.

Anyways, I'm here in RI, with a 2008 Saturn SKY Redline. I would like to share my compound turbo build with you guys, and I'm hoping that it might also spark interest to some of you to do the same with your platform.

Feel free to help me out with some of your knowledge since I know the tuners and builders of EVO are some of the best there is in today's tuner platform.


I have a 2008 Saturn Sky Redline. I used to have a gt3582r that produced 403whp and 383ft-lbs.














but right now, we are building a compound turbo set-up, which will be the first and ONLY Saturn Sky/Pontiact Solstice/ecotec engines in the world.


COMPOUND TURBO SET-UP:
Garrett GT4294R (1.0 turbine A/R) and Garrett Gt2871R (.63 Tial turbine housing A/R). Both turbos have v-band – and CRYO-TREATED!!!
BTF tubular manifold (321 stainless steel)
BTF 4” downpipe (321 stainless steel)
BTF recirculating dump tube (321 stainless steel)
BTF charge pipes
Turbosmart Power-Gate60 – controls GT2871R turbo
Turbosmart Comp-Gate40 – controls GT4094R turbo
Turbosmart Race Port BOV
Turbosmart Eboost2 60psi electronic boost controller

321 Stainless Steel tubular manifold, downpipe(Swaintech coated and DEI titanium wrapped)
Werks RACE Intercooler – 15” x 3” x 24”
AEM water-methanol kit
DEI Cry02 intercooler spray kit


BATES ENGINEERING RACE BLOCK:
Bates Sleeved block
Bored ,honed, Aligned hone
Decked
Bates Main Studs
Bates Balance shafts
Bates main bearings
Bates chain tensioner spring
Bates billet oil pump gear
LNF camshaft
K1 rods and Wiseco pistons installed

SMG HAND PORTED RACE HEAD:
Supertech 35.5 mm oversized valves
Supertech 78 lb springs (cryo treated)
Supertech retainers/keepers
Bates Head Studs
Bates Rocker Arms (cryo treated)
Aggressive Headwork
Ported and Polished Throttle body and Manifold



FUEL Set-Up:
WERKS custom race manifold w/ port injection
RMR secondary fuel rail
RC engineering 42lb injectors
Split Sec extra injector controller
Nitrous Express SAFE fuel System (extra fuel cell w/ fuel pump and adjustable fpr)
Deatsch Werks 300lph fuel pump
ZZP stage 1 cams w/ big fuel lobe



LIBERTY GEARS/NITROFREEZE Transmission and Drivetrain:
Spec Stage 3+ clutch w/ 11lb Flywheel (Cryo-Treated)
Polished hub and sliders, gear/synchro set (shot peened and cryo-treated)
Pinion, driveshaft, axles, and rear differential (cryo-treated)
Driveshaft Shop 600hp Axles
18"x10" Forgestar Wheels w/ Nitto NTO5 295/35/18



First, I wanted to thank Dave of WERKS for sponsoring me with the Race Intercooler

I also wanted to give thanks to the following for some feedbacks and insights about the compound turbo set-up planning:
- Dave of DDM
- Shabby
- Marc of Boost logic – you can youtube him (marc compound turbo). He has a very successful compound turbo set-up.
- Kevin Jewer – owner of 1991 Eagle Talon compound turbo set-up (T3 50 trim and T6 s475 w/ 1.06 AR) – 8.97sec @ 156mph Thank you for all the step-by-step answers that you provided me!!! You have been my on-line mentor!!!


Finally, I wanted to give thanks to my my main sponsors/tuner:
Baldturbofreak aka BTF BTF racing will sponsor me for this build. Rick helped me out choose the turbos for my compound turbo set-up, and provided me with the turbos. He will custom fabricate me a tubular manifold and the compound turbo set-up.

Fred of SMG Motoring Fred is my main tuner. He will install the compound turbo set-up, and will relocate TONS of stuff to fit this compound turbo set-up.

Ryan of Nitrofreeze for full-sponsorship of the cryogenic treatment of all my parts!!!

Vince of burnsstainless.com for sponsorship of all the stainless steel parts for this build.



Late last year, since SMG had already successfully twincharged the cobalts, by having a rear mount a turbo…………I asked myself, how about adding another turbo on my set-up and mount it at the rear?

So Fred and I started talking about mounting a k04 turbo at the rear, and do a sequential turbo set-up. The k04 turbo will spool fast, and will help have a more responsive car. But after talking to Dave of DDM, Shabby, and Marc, the plan of having a sequential set-up will not work-out as planned and will be very complicated to run smoothly. So I scratched that the plan right away.



So here’s the compound turbo set-up flow:

Exhaust manifold > small turbo (turbine) and powers the engine > excess exhaust gases goes to dp/wastegate > > big turbo (turbine) > big turbo compressor > compressed/cold air goes to small turbo (compressor inlet) > small turbo (compressor outlet) > Intercooler > engine


We are hoping to boost this set-up at around 43-45psi, since the RACE Block can handle it without even sweating. Race block can easily handle 1000 whp. If things go smoothly, the set-up will flow at least 80 lb/min …………and will produce at least 600 whp. It will be an ultimate street machine that will be competitive in auto crossing, drag racing, and road racing.

Will spool from 2800 rpm all the way to 8000 rpm 


GT2871R will be boosting 28psi and GT4094R will be boosting at around 15psi.

Total boost pressure will be 43-45psi or more



BTF will start working on the project mid of November 2011. After he finish the manifold, it wil be sent all the hot sides to SWAINTECH for ceramic coating

SMG will be working on the head, transmission, all necessary relocations, and everything will start mid mid 2011 as well.

BTF and SMG collaboration!

We are hoping to finish the whole project and tune the beast before the end of Summer 2012

There will be lots of trial and error during the build, and same goes to the tuning. But that’s normal to every build, especially on a very crazy build like this. But whatever it takes, we will complete this project!!!


LIPSTICK will strive to be the first LNF engine in the 700hp range that will be a daily driver. FIRST EVER compound turbo LNF set-up!!!!



To learn more about compound turbo, here’s my buddy Marc:

YouTube - Marc's 2JZ Turbo Compound Setup

YouTube - Marc's Track run with Commentary

To follow this compound turbo build, you can go to this link: Antonio Sky | Facebook

Or search “Antonio Sky” on facebook

SKY888

Finally removed the transmission and will be sending every part to be CRYO-TREATED Spec Flywheel and pressure plate will also Cryo-treated. Engine will be pulled out tonight!






Engine pulled out last night

SKY888

got the intake manifold fabricated:




a photo of a 1000 whp race block. Shot peened and cryo-treated.

BATES Engineering block
custom Wiseco pistons
custom K1 rods
custom k1 crankshaft













tranny being worked on......and will soon get shot peened, polished, and cryo-treated:

SKY888

some teaser shots of my compound manifold set-up!





clearance for a 4" downpipe





only the gt2871r showing.............the gt4294r will be attached soon!

SKY888

Now both the gt2871r turbo and the gt4294r turbos are positioned inside the engine bay!


Once the god forsaken notches required for the gate placements (the 60mm primary uses 2.5" pipe man, it's fawk ing huge) are finished so they have no seams, serious bracing will be constructed across the top of the Valve cover and to the turbos, headers and specifically where the gates attach.

They are so far away from the engine they will be prone to oscillation at certain frequencies and eventually cracking without significant bracing and double wall at the gate attachment points.

THEN having guaranteed placement of key components and they're v-band orientation, we will add 3 flex/expansion bellows to allow for thermal expansion and to some degree vibration/misalignment.

The proper kind of flex bellow, NOT the braided variety. those have no place upstream of a turbo!

SKY888

Aeroforce helped me out and sent me a Pyrometer kit and a pair of EGT probes.



Just picked them up today!
Last year, I tried having my intercooler sprayer be annodized red, but the nice color easily faded away due to the harsh conditions (rocks/chips, rain, heat, etc) it faces every single day. This time, I had it powdercoated RED, and it will be more durable.
The stock driveshaft and the DSS rear axles were sprayed with Thermoplastic Spray and also clear coated. This will make sure that they'll no longer have surface rust.

SKY888

If you're trying to flow more than 70 lb/min, and trying to get more than 600whp, unfortunately our stock fuel system will not be able to support it.
Even if we can raise our fuel pressure to 2800psi thru trifecta tune/HPT tune, the stock fuel system, still have a hard time.
Water/Meth kits are nice, and will help cool the air and prevents detonation. If you use 100% pure meth, it will help add more fuel, but it can only do so much even if you add 4 injectors on the manifold. I was talking to Chance from Devil's own, and he advised me that if I really want to add more fuel during high boost/more air...........water/meth spray is not the way to go.
So after consulting with different LNF tuners, I ended up going with PORT INJECTION using a secondary fuel rail. I will also use an additional fuel cell so I don't have to tap from the stock fuel tank line.
This will make sure that I will have enough fuel injection during high boost/more air during high rpms.

rossmachineracing = -8 fuel rail, brackets, and bungs
rceng = set of 70 lb RC engineering injectors
nitrousexpress = SAFE fuel system w/ high output fuel pump and adjustable fuel pressure regulator
splitsec = Additional Injectors Controller and R4 Software

SKY888

burn's stainless sent me a pair of ultra light race mufflers:
Ultra-Light Stainless muffler features:
•New updated design for 2009!
•New "floating" core allows for easier rebuilds
•New 2-Stage (2S) mufflers provide additional sound attenuation
•Remarkably light weight and extremely durable
•Built to the highest quality standards
•100% stainless construction
•Completely TIG welded
•Easily replaceable high temperature packing
•Stainless steel scrubble packing also available (call)
•Inside diameters from 2" all the way to 5"
•Can be built to custom lengths (call)
•Discounted and old style mufflers available below
•* Packed with scrubble
•**Packed with scrubble/glasmat

Inlet/Outlet Diameter: 3.00"
Body Outer Diameter: 4.50"
Overall Length: 17"
Weight (lb): 3.29
Once we figure out if we'll use 3" or 4" downpipe (depending on the engine fitting), then Burns Stainless will send us 304 stainless steel pipes for Lipstick's custom exhaust.







more upgrades arrived recently:

3" exhaust and shiny new dual tips!!!

WERKS Race Intercooler and Black thermal coating and Deatsch Werks 300 lph fuel pump!!!

Valve cover came today with a new powdercoat.

SKY888

Turbosmart is currently helping me out with my build and sent me:
Eboost 2 electronic boost controller - 60max psi
2011 Race Port Bov
Comp-Gate 40 wastegate
Power-Gate 60 wastegate

So that's the reason why I have to remove all of my Tial products since they're a direct competitor

here are some of the photos:
Eboost controller (66mm)



2011 Race Port Blow off Valve (very small and light)



check out the size difference between my old Tial Q bov and the 2011 Race Port BOV (they're both 50mm though)

erald01

iTrader: (5)

nice set up and fabrication, i have seen a few dsm guys do the compound turbo set up. Btw whats the deal with the custom pistons? Why is the surface shaped that way?

SKY888

these cams together with my secondary fuel system will compliment each other to provide enough fuel for lipstick!

SKY888

this will be the set of wheels handling the power....
I received the set of Forgestar F14 Flow-formed wheels about 2 months ago, but didnt open them until recently since I was very busy.

Matte black 18" x 10" on all corners, only 18 lbs each
they'll be wrapped with Nitto NT05 295/35/18 which will be perfect for my application
Here are some sneak peak photos....







They'll be responsible for putting the power to the ground.


fresh from Road Force balancing.....

SKY888

600whp Rear Axle kit from Driveshaft shop

Rear axle upgrade includes larger 34 spline high grade aircraft quality center bars, tripod style billet inner CV's with chromoly spline into the differential and a pair of races to convert the outer CV to fit the larger 34 spline bars. Kit also includes boots, clamps and grease.










All shafts will be dropped off to NITROFREEZE today for cryo-treatment

SKY888

LNF ecotec engines are Direct Injected engines.

That's why the pistons look different compared to FI engines.

SKY888

anyways, some parts that just came from being cryo-treated:
Bates Billet Oil pump gears and Bates Chain tensioner and supertech valve kit









supertech oversized valves, 78# springs, retainers