Turbo FZ Build

[mittens]

No exhaust leaks or anything one of my water lines feeding the new Bottom fitting on the up pipe has the hose rubbing a spot, so will have to address that before it rubs a hole in the hose. But other then that seems all there.

Just need to dial up boost, adjust fuel and then see where RPMS are...

[moparguy]

Love following your build Mittens, kinda temping to go to the blue side. How does the mid range hit, opposed to say a 20lb s/c SVHO?

[mittens]

Well I have only ever had a C1 wheel in a SHO, & a stock wheel SVHO at 9300. Making 18lbs peak to compair it to.
but it hits harder everywhere other then idle to 2-3k & that's only less then a second before all hell breaks loose ha. Full boost is instant

[moparguy]

Well I have only ever had a C1 wheel in a SHO, & a stock wheel SVHO at 9300. Making 18lbs peak to compair it to.
but it hits harder everywhere other then idle to 2-3k & that's only less then a second before all hell breaks loose ha. Full boost is instant

Giggity Giggity

[Reaper9789]

Giggity Giggity

Here is a short run of mine during some tuning.

https://youtu.be/_UzVtj0LA7E

[mittens]

I wish the GoPro would show the boost gauge haha. Looks like I see 19-22 lbs dancing mostly around 21 on the pull?

[mittens]

Finally got the l stainless plug tapped. What a bitch taping stainless.

So now the factory exhaust water temp sensor mounts into a water jacket plug. So if for some reason I loose water flow to the turbo jackets/turbo ect.. it will get hot & trip like factory. Before this sensors was just zip tied up in bilge. So now back monitoring the water temps cooling the turbo stuff. Hopefully works like I assume. So far have not seen turbo pipes get over 137 so should be well below the range & only trip if no water flow.

[mittens]

Few updates.
I kept turning up boost & never getting to 20 lbs.... swapped to the "High Boost" waste gate actuator, and working much better 14.5 lbs on spring pressure & boost controller is working as instructions indicate.
Tried it at 5mm pre load & while works, I had boost spikes, so now at 3mm preload & the pool worst spikes are 21 lbs & WOT pass is 19.5-20.2... may turn it a click or to more for more solid 20 but watching spikes too.

AFRs seems to be the same as before fuel pressure vs temp wise. Boost can be up or down & tune is keeping it the same.
54 psi 60-70 degrees
52 psi 70-80 degrees
50 psi 80+ degrees
49 psi == 95 +


Finally bit the bullet & bought a Pet tach. My searon was working but sometimes a pass would not show what it peaked at & in general was not updating like I needed to dial it in... came this far... so got one. 3D printing mounts but have one that is working while I make some changes.. today was first day out with new tach.. a lot better. The live display is delayed but the peak recall is not.. great for dialing it in... & over all a lot better.

90 degrees Alabama humidity (57%), water temp 79. Cooler of beer, 3/4( closing in on 1/2 tank). My 250lbs ass.

93.3mph @ 9060 RPMs.. so can use 200-250 more RPMs Not sure weather I want to push another lbs (probably not on 93, but may try solid 20 lbs WOT just to see if it gets it there) or a FX nozzle ?? (2mm bigger). Would rather not depitch as I just removed a 13/18.5 & it was all over the limiter at 18 lbs.

shooting for 9300 WOT in heat & can dial it back when colder if needed. Other wise I can leave it & probably gain that back on colder days. But living in Alabama a lot of my riding it 80-95 degree summer so would rather it be dialed in for heat, back it down in fall va dialed in for 2-3 cooler days & lacking RPM all summer.

[mittens]

Little update..... Took ski out with GP1800 Nozzle ( 5 degree / 87mm ), removed my 3degree/85mm and the 2 degree wedge.

Hot day 98 degrees/ 82 degrees water temp.
Ski picked up rpms to 9240 RPMS. was 100% full of fuel and both coolers of beer, and tools. Ran 91.4mph while this is not some best. Its solid foe how loaded and hot it was that day. last it ran 93.6 same 9200ish RPMS. stopped playing and enjoyed the day.

Next day, was out for some riding and before the ride I let my best friend ride it after he asked me to. Boating friend, dock mate directly behind me on dock , ski buddy as well. Very close friend. Needless to day, I said sure, with instructions. Don’t hold it wide open long, don’t go far or out of sight, and don’t go behind the island. He takes off directly behind the island, i hear it go WOT until I could not hear it any more.... then 2-3 min later, myself, his son, 2-3 other friends all standing on the beach see it coming from the other end of the island WOT could hear it screaming... saying out loud man that’s a long run,.... come on man WTF... then basically as he got back to us (full circle around the island 6 miles) sounds changed, smoke show out the back... staying in it still then it shuts off... I knew it was DONE. Borrowed a ski from buddy on beach and went out to it. Smoke coming from under the seat with him looking at it like WTF. I asked if it was on fire, he said no, put the seat back on and towed it to the beach. Oil everywhere all oil lines connected, metal in hull. I kept my composure, was quite, and got myself and ski out of situation and home. I am proud I did not kill, flip out or ruin a friendship right then and there. I can be a angry loud person, so it was some self-control. a lot of emotions, time, money, blood and sweat into that ski...

Pulled plugs when I got home, bore scoped down 1-2-3-4... #4 I was not looking at a piston but a rod and crank....Next day I stayed away from river/boat and took ski apart and motor out. Number 4 piston was gone. Window in block where crank had shoved piston chucks out the side (behind the starter), rod was bent but still in the jug (was expecting to see it out the block), Bent all 4 valves on that one hole, oil pump trashed from all the metal being sent through it, cooler trashed as well, turbo turbine has chucks out of turbine and bearing all loose from contaminated oil/ and hitting things. So basically everything was taken out. Will post some carnage pics. From what I see ski was just abused and exhaust gas temps finally took out number 4 piston and then all hell broke loose. Don’t think it just failed ski and set up has been solid for 2 years and showed no signs or issues until 9300 rpms for 6 miles strait. I have go pro video of him as it was running so could verify the amount of abuse.

[mittens]

Can see here all the metal in the Sump of pan, clogging the screen on the oil pipe, damaged oil pump, 2 main parts of piston #4, bend rod, and general crap... the mount of metal everywhere from it still running for a bit WOT with number 4 gone sucked. I found part of a Ring in the sump as well.

[mittens]

So after accepting most is all ruined Mailed off turbo for repair. Started ordering replacement stuff. I wanted to build a short block but all my local places were 4 month back log for balancing a rotating assembly, and cost wise (since I had to buy a block) was around 2K more. And everyone in the business seemed to agree, unless I was going to change fuels and push past 20ish lbs of boost the stock short block was fine.

OEM Shortblock from Yamaha
2021+ Bare head from Yamaha (hope to not have cracking issue)
Set of used GP1800 valves
New Oil Pipe
New NA oil Pump
New Timing chain
New Riva Valve seals
New head bolts
New head gasket
New gaskets for oil pipe, chain tensioner, etc...
Fly wheel tool, crank tool, coupler tool.

I re-used my springs and Riva Retainers (few new ones for the ones that took hits just for peace of mind).

Also swapped to new style Oil cooler while I was replacing oil cooler I had a 2016 stacked disks that are prone to leaking anyway.

I had time so dropped Valve cover, both manifolds off, and turbo compressor cover off at Powder Coaters to clean it up some too.

Lapped valves in the new head, shimmed in on bench, then recheck/shimmed once torqued to head. Then assembled parts.

I also had to replace Stubby/transfer shaft, stator bearing and seal as it did not come apart like I though. live an learn.

I had motor done and back in before turbo came back. That was a issue as Borg Warner is not making EFRs right now / what I had currently and had to find what I needed. So after alot searching and back and forth with dealers, they finally found me a 62/58 aluminum housing, they milled it to fit my 67 wheel. So now I have a 67/58 again in Aluminum. All is installed, ski starts and codes self cleared and ready for water test / break it.

During all this I finalled scored a R&D Intake grate haha. I will worry about installing that and testing for any gains over the modded stock grate after the ski is broke in and all is back to normal.

[ptscon]

Shit that blows. Your buddy needs to be buying you beer for eternity.

[mittens]

Shit that blows. Your buddy needs to be buying you beer for eternity.

I did the best I could on keeping prices down. And he did step up & paid for the majority of the parts. I covered some things & all the special tools & did all my own labor. It was not cheap on either side, but he did not leave me hanging either. We are still friends. And am happy that we both did not loose our cool, talked about it, & handled it well. A lot of money in a random beer drinking toy. Let alone a lot of money between close friends.


Time wise he blew it up June 17th
I installed new motor August 7th
Turbo delivered & finished install August 20th.
So basically 2 months down in middle of summer. Hopefully water testing tomorrow.

[JCIBELLA]

Shit that blows. Your buddy needs to be buying you beer for eternity.

A real friend would offer to help pay for atleast some of the parts. This is why I don't let anyone drive my ski.

[mittens]

Took it to the water today. Rode the whole 90 min break in period. With some stops for 10-20mm cool downs. Gave it a few WOT for a few seconds in the last 30 min, and a few rpm spikes to 6-7k in the last 1/2 or so. First 30-45mph nothing above 5k. WOT after with low boost (14 lbs), 8500 rpm's, 84mph. Felt smooth. No leaks or issues... will ride tomorrow with some skis & turn the boost back up to 20. Then change the oil & filter after tomorrow. Hopefully all back to normal. Then can play with grate. See if It will break 95. Probably not. Just be happy to get back to clean & running 93.