On3 non ac kit w 78/75, Tick ls2 Stage 2 Cam, E85 Build ** Updated 5-22-18 **
 

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Track update**** https://ls1tech.com/forums/forced-in...-no-boost.html ****



Hey Guys just wanted to share my build/experience with the On3 kit and my first turbo build. I got a lot of knowledge through everybody threads and post from this site. Im coming from nitrous set ups, I had it for about a year and half and I figure it was time to upgrade to FI. My first intentions were to go with a pro-charger but the one I was gonna pick up guy tried to screw me at the last minute so I back out. I figured this kit was a good entry level kit to get me going since this was my first time with FI. I knew nothing about turbos beforehand and I wanted to prove to my self that I could get this done by my self of course with a lot of reading and research. The build tear down to start up took a lil less than a month started 9th and fired it up the 22nd. Waiting for parts and ordering more parts. If your going into this thinking all you need in the kit and what ever come with it think again there are a lot of little things you will need.

Car specs

Iron block
Th400
12 bolt
799 P&P heads
Fast Intake

Whats going in
Tick stg 2 turbo cam
Deka 80s
Dual 340 pumps on hobbs
78/75 turbo 8# gate spring
E85

Like stated I started the 9th taking the front clip off and swapping out cams and prepping the intake for the map sensor and seeing how I am going to route the scavenge pump.

https://cimg7.ibsrv.net/gimg/ls1tech...f53e543089.jpg


I Also took this time to wire the derale fans and mount them to the radiator. I used the blue signal wire from the old fan harness to trigger the relays for the fans. I also re routed the power wire that ran in front of the fan and the fan connector to the wire loom that is behind the rad.


https://cimg2.ibsrv.net/gimg/ls1tech...605d7b0c10.jpg

Finally the kit cam in on the 16th

https://cimg3.ibsrv.net/gimg/ls1tech...55d59e1dbd.jpg
https://cimg4.ibsrv.net/gimg/ls1tech...bbf78c66c4.jpg
I wasted no time in starting i wrapped the hot side
https://cimg5.ibsrv.net/gimg/ls1tech...b3d09be7b5.jpg

should of fit it before wrapping it.

Here is what the bay looked like before I started installing everything I painted the fast wrinkle black.
https://cimg8.ibsrv.net/gimg/ls1tech...2e46bfe91e.jpg

Next was the manifold install. Here is something y'all need to know. They do not provided the header to cross over bolts. They tell you in the instruction to reuse the stock manifold bolts that come on stock your header manifolds. I did not have any stock manifolds so i had to buy some from the local auto zone. other than that they went in fine. But i did have to notch the k member on the passenger side for 1 bolt. But other than that the cross over pipe went on fine.
https://cimg0.ibsrv.net/gimg/ls1tech...95ef3e5c3b.jpg


https://cimg2.ibsrv.net/gimg/ls1tech...45eea7f2d1.jpg

https://cimg4.ibsrv.net/gimg/ls1tech...8703ada33e.jpg

Next was mounting the turbo and seeing down pipe clearance. Everything fit fine and had plenty off room. I would advice that if you have an A4 to put some sleeve insulation on the tranny lines as the run close to the down pipe.
https://cimg5.ibsrv.net/gimg/ls1tech...e327073992.jpg


Next was the mounting of the scavenge pump and relocated the horns and the ac vacuum thing. This is how i did mine.
https://cimg1.ibsrv.net/gimg/ls1tech...047f146f22.jpg

I also re mounted my trans cooler.

https://cimg5.ibsrv.net/gimg/ls1tech...d4b1b01d83.jpg

Next was test fitting the cold side, oil feed and blanket .Everything fit great. I mounted the intercooler with 2 piece of steel mounting to the nose support. The bracket I made for the transmission cooler help out a lot and kept it from sagging.
https://cimg7.ibsrv.net/gimg/ls1tech...77b3b1d03c.jpg

https://cimg9.ibsrv.net/gimg/ls1tech...905c7b09e5.jpg

After everything was fitted it was time to test fit the bumper. I also cut out the plate filler part.
https://cimg2.ibsrv.net/gimg/ls1tech...cd30906c7a.jpg


https://cimg4.ibsrv.net/gimg/ls1tech...93b00a4f40.jpg

Finally it was time to put the everything back in radiator/bumper/hoses/belt. for the belt i have a 25% UDP and this is the belt I used. I also used an lt1 shroud. Also a pic of clearance with the turbo from the radiator.
https://cimg2.ibsrv.net/gimg/ls1tech...db6be61fd6.jpg


https://cimg4.ibsrv.net/gimg/ls1tech...4a4c4b60be.jpg

https://cimg5.ibsrv.net/gimg/ls1tech...f87a3c4e15.jpg

https://cimg7.ibsrv.net/gimg/ls1tech...3a5b129509.jpg

https://cimg8.ibsrv.net/gimg/ls1tech...7480edd703.jpg

Finally it was start up time.




Sadly I am still waiting on my fuel system from racetronix. But once its in I will update on that. I will be getting there dual pump harness and there 340 pumps.

Any question feel free to ask. I have plenty more pictures as I documented the build. But only attached what i felt was needed.

I have the same cam, it sounds amazing. It makes good power down low on motor. But i guess thats where the turbo kicks in at higher rpms. Im doing a similar build with ac.

I strongly recommend painting the wrap. I left my lava wrap unpainted and it continues to shed fiberglass everywhere in the engine bay.

cool build!

I'm getting near the end of a turbo build almost identical to yours. Same on3 kit and cam on a 5.3. I'm just trying to decide which direction to go with the fuel system. It's definitely going to have a double pump. Are you upgrading your fuel lines and regulator? I've read you almost have to when using E85.

No I will be using stock lines.

Just an update. Finally fuel system came in.
https://cimg7.ibsrv.net/gimg/ls1tech...4438999a31.jpg

All in all the dual pump harness was pretty simple to plug in. All I really had to do was remove the connectors to the fuel level sender over to the new harness connector that connects to the bulk head connector. Also on the intermediate there are 3 wire that you plug into the factory harness on the that behind the passenger driver side seat. 2 purple and black are for the fuel level sender and 1 grey is for the trigger for the relays. There is no ground this is replaced with a stud witch gets its ground from the new harness. For the bucket I just trimmed the factory bucket for the 98. I cut the bottom to just clear the socks but left enough so that the dual pump bracket has something to sit on.
https://cimg5.ibsrv.net/gimg/ls1tech...62a61df6e7.jpg

Putting it back in the car it put up a good fight but it does go in. Now I just gotta wait for a spot to open up so I can go get the car tuned.

You mentioned you have a 98, are you still using the 98 ecu. I was thinking of running a maf just for the extra data it could provide for tuning

Yep still running the 98 ecu.

Just an update after talking to my tuner he recommend bigger injector. So I decided to give our sponsors HPI or high performance injectors a try. Answered all my questions and they have free 2-day shipping ordered it Thursday got here Saturday. The injections look awesome high-quality and well-packaged and it does include a flow sheet. I went with the 96lb injector switch flow about 110 at our LS base pressure.

https://cimg9.ibsrv.net/gimg/ls1tech...14edeeabff.jpg

Good looking build keep it up. Any goals set power wise? What boost you planning to run?

Boost I will start on gate 8 psi and go from there. Power wise I'm really not into Dyno numbers. On my last nitrous setup on the Mustang dyno it made 540 w/100 shot on the Mustang Dyno through a 12 bolt and th400 but went 10.3 @128 with a 1.5x 60ft @3700 rw so anything above that I'll be happy

FGTrtttt

I've seen better builds on sloppy mechanics.

Nice build. Good to see you didn't have issues with the On3 kit.

Just an update. Finally got around to starting to tune it. At first was getting quite of bit of knock but this was due to the down pipe hitting the k when the motor would flex a little. Also remember the down pipe fitment is tight, so what I did I took it out and marked were it was hitting on the pipe and heated it up and dented the down pipe were it was hitting. After that no more false knock.

Here is the video of the pulls I did. The info on the pulls are in the title of the video.

sounds good!

Nice work! I am not sure how you can stand ditching the AC in Texas. I am thinking about their AC kit, but evidently I need to get a new K-member to do that.

Thanks guy

The non AC kit doesn't bother much as it not the daily. I also really drive it during the day unless there an event or a local show. But one awesome thing is the fans with the stock rad are keeping temps in check, when I did drive it in the day outside was like 101 and temps never got about 205 even after back to back pulls.