Turbo VVVVVRRRROOMMM (or not, I like my MPG).
 

This thread is about turbocharging my Insight, I forgot to put it in the title.

I had initially planned to supercharge with an AMR500 but, there was some added complexity that made the project not worth it.

Anyway, I have been slowly accumulating parts over the past 6-8 months and I finally purchased the last piece, the turbo, for super cheap from a friend.

My goal is to run 10psi out of a RHB31/VZ21 turbocharger. It's perfect size for the insight, will produce 10lbs by 1750rpm and can put out about 105hp at its absolute limit.

I have a AEM FI/C-6 with a custom Boomslang Harness that will be controlling Toyota camry injectors (255cc vs 145 stock) to keep me from running lean, or stressing the stock ones over 80% duty cycle. The injectors are the exact physical size as OEM Insight ones and are plug and play to the OEM harness. It will also allow me to fool the stock O2 sensor and MAP sensor so the stock ECU isn't fighting me to control fuel under boost, but runs normally under non-boost conditions.

I chose now to make this thread as I wasn't fully sure when I was going to start on this project, but yesterday I benched the insight due to the ISB getting so bad I can't even hear myself think while driving, so while I pull that and await a new one from Scott, I'm going to start fabricating and mounting everything.


Things done so far:
Installed AEM UEGO gauge(Air/fuel ratio).
Installed Boost gauge.
Drilled intake manifold and installed barbs for vacuum line for Boost gauge/AEM F/IC-6.
Routed all vacuum lines.
Installed F/IC-6.
Hooked up AFR gauge to the AEM F/IC-6.

Things left to do.

Move battery to the rear.
Remove stock intake/upper exhaust.
Scavenge flanges from old upper cat.
Install T fitting on oil pressure sender.
Fabricate oil feed line.
Fabricate manifold to turbo piping and turbo downpipe.
Remove oil pan and drill/tap it for oil return.
Fabricate intake charge piping and mount for intercooler.
Install AIT sensor.
Install spark plugs (have 2 heat ranges colder plugs).
Lots and lots of tuning.

Subscribed.

I was looking around for info on your turbo... I've found pages that say "up to 100 hp" and "up to 600cc."

So if you're not looking make more than 100 hp, you can use a turbo that would normally be for a volumetrically smaller engine?

This thing is adorable:
http://www.ecotrons.com/wp-content/u...bo-VZ21-02.jpg

In this case, I wonder if a kei car turbo setup, like the package from a Mitusbishi Dangan ZZ would be a nice kit to adapt to an Insight. Stock engine it's on is a 658cc three (with 5 valves per cylinder!):
http://1.bp.blogspot.com/-3wGpUsav_f...BLACK%2B17.jpg

I mean, look at that little intercooler!

Sam

I chose the rhb31/vz21 because of many reasons.

The insight is tall geared. I want boost down low.

This turbo is good for 100-900cc.

Chevy used this turbo on the Chevy Sprint.

It will make 10lbs at 1750rpm.

According to the compressor maps, I fall in the perfect spot at 10psi.

My goal is 40-50% power increase, which should be right about the limit of the turbo. The insight makes 67hp stock (probably closer to 55 after friction losses). And even at 67hp, 50% = 33 which = 100hp.

Baldo, I used that turbo for a while and it is perfect for what you want. If you are just driving without load (cruising) you are just out of boost but as soon as you need it it spools right up. I think the rhb series are ball bearing. I will be following your project and good luck.

This one is journal, but yea it's gonna be amazing. Thanks!


Tomorrow I plan on taking care of #1 on the to do list. Then larger injectors will be installed. Hopefully that will all be done tomorrow.

Are you planning any eco features like intercooler-bypass for faster warmup?

Nah, the intake charge will already be warm as it is because of the turbo. Because of the way the intercooler is going to be mounted, it won't get any airflow except from a fan I'm going to mount on it. I'll leave the fan off unless intake Temps get above 150F when I don't plan on using boost (like just casual cruising on the highway, or on startup) so I guess that in itself will help.

Got some more progress done tonight!

I figured out why I couldn't adjust O2 voltage with my FI/C-6. Boomslang tapped the wrong wire. I had to tap #10(?) wire, which is red, on plug D of the ecu harness instead of whatever wire they had tapped, and presto! It worked!

So onto the next step. I revved the car to 2000 and adjust voltages, then wrote down the corresponding afr and STFT.

I then installed my 248cc Toyota Camry plug and play injectors, made the necessary adjustments to my fuel map and BAM! runs great, definitely idles smoother and my STFT are +/- 5% (within acceptable limits).

Next step, is to fabricate turbo manifolds and what not. More to come this week!


A little extra: The car definitely idles smoother. I think this is because the stock Honda Insight injectors are only 4 hole, and the Camry ones are 12-hole. I am now getting better fuel atomization as a result.

Great project! Are you in a Change of Ownership Area for smog, or are you going to swap the turbo out and/or go some other route?