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Old 09-01-2017, 01:52 PM   #1
FenixFallen
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D1SC build

Hi all, I didn't start a thread when I began my build but now it's pretty much done. Here's what's in it:

Stock longblock, 85,000 miles
D1SC Procharger head unit, 4.15" pulley, bigger race intercooler, Big Red Race bypass valve
Anderson Power Pipe
ported/polished stock length intake manifold, Roy's 3/8" spacer
Accufab 60mm twin throttle body
Cobra 39lb injectors
NGK TR6 spark plugs
VMP 5000 slot style MAF
Lethal performance budget return style fuel system with twin 255lph Walbro pumps in tank.
MAC longtube headers,catless H pipe and catback, 2.5" pipes
PLX wideband
JLT catch can, both PCV ports routed into it and then into the intake pipe before the blower
Treadstone Vacuum block, Boomba check valves on everything except the fuel regulator.

I managed to get it all to hook up even with the 3 point strut brace with a 45 degree bend coupler at the throttle body. Had to grind a bit off the bumper support things like other people have, had to open up the hole into the fender to get the giant power pipe to fit with the pipe going into the intake manifold. Had to grind a bit of the shaker on the underside to make room for the coolant fill port, and fabricate my own shaker mounting brackets because the used kit didn't come with any. Also had to cut away some of my bumper underneath to make room for the plumbing.

Couple questions I have left:
There's a hose going into the intake manifold just under the throttle body which I'm assuming is part of the EVAP system. I had put a check valve on this line too but I noticed that the line going between the check valve and the tank has collapsed. I took the check valve out and it seems to collapse anyway with the car at idle. Is this line supposed to be check valved or not? It doesn't seem to idle any differently with or without the check valve, and ran fine with it in.



What should I expect to make power wise? I've got a dyno tuning appointment in a couple weeks, these guys specialize in mustangs so I don't think there's any danger. I'm just worried because I've read the stock engine internals can't handle much more than 475 rwhp reliably, so I'm hoping with the giant 4.15" pulley it'll only be somewhere between 400-450. on a different dyno, the car pulled 297 rwhp with no supercharger, just the intake spacer, exhaust, K&N filter and a tune from american muscle.



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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.

Last edited by FenixFallen; 09-01-2017 at 07:09 PM.
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Old 09-01-2017, 01:55 PM   #2
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Re: D1SC build





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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 09-01-2017, 02:12 PM   #3
DSG2003Mach1
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Re: D1SC build

the only place you need a check valve is if you have the driver side PCV hose going from valve cover to intake. Thats the only one I run and I have no issues. If that hose is collapsing at idle its probably due to be replaced, if I remember correctly you may need to pull the pass fender liner to to get to the other end of it
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Old 09-01-2017, 06:55 PM   #4
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Re: D1SC build

Ok, I guess I was afraid of things getting pressurized if they weren't intended to be boosted. Might have gone a little overboard then lol. I'll pull that liner out this weekend then and see what length I need. Thanks for the advice, that's reassuring!
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 09-01-2017, 09:33 PM   #5
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Re: D1SC build

trace that line back into the fender opening and double check before pulling out the liner just incase.

what size fittings did you get with the vacuum block? I ordered one but I got the wrong stinking size fittings for the stock size vacuum lines
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Old 09-02-2017, 11:01 AM   #6
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Re: D1SC build

I want to say the stock vacuum lines were 3/16. The ports coming off of the intake manifold are 3/8, except for the PCV port which is 3/4. Here is a link to the vacuum block I bought:

http://www.treadstoneperformance.com...t+Vacuum+Block

The big fittings are 3/8, The smaller fittings on it are 5/32, and the silicone hose I got was 4mm from them. It'll fit over 3/16, just use some liquid silicone to lube the lines up before you slip them on. I had tried to find some tiny hose clamps but the ones I found are just a hair too small to fit over the lines without damaging them.

I used the pcv port on the intake manifold exclusively for the bypass valve's vacuum.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 09-02-2017, 11:13 AM   #7
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Re: D1SC build

This is going to be a good combo.
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Old 09-24-2017, 11:37 AM   #8
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Re: D1SC build

After the dyno tuning session, my final numbers were 451 torque @4900 rpm and 483 horse @ 6100 rpm, at 8.9 lbs of boost. Big thanks to Pete at Performance Dyno in Loudon NH, he really seems to know these cars inside and out. Apparently I'm making too much power, so he cut the timing back a lot and reduced my rev limiter to 6600. Was worried about my stock internals but as long as I stay away from 6k rpms it should be fine. Next year I'm going to plan on getting that built stroker the cams it needs and a built transmission, then once that's installed I can play around with the supercharger some more.

The car is a lot more fun to drive now, not that it wasn't fun before. Forced induction makes it a whole different animal!
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IMG_2849.jpg  
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-14-2017, 10:23 PM   #9
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Re: D1SC build

Quote:
Originally Posted by FenixFallen View Post
After the dyno tuning session, my final numbers were 451 torque @4900 rpm and 483 horse @ 6100 rpm, at 8.9 lbs of boost. Big thanks to Pete at Performance Dyno in Loudon NH, he really seems to know these cars inside and out. Apparently I'm making too much power, so he cut the timing back a lot and reduced my rev limiter to 6600. Was worried about my stock internals but as long as I stay away from 6k rpms it should be fine. Next year I'm going to plan on getting that built stroker the cams it needs and a built transmission, then once that's installed I can play around with the supercharger some more.

The car is a lot more fun to drive now, not that it wasn't fun before. Forced induction makes it a whole different animal!
Good numbers. Yes, I agree a little much for stock rods. Great job on the build
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Old 10-16-2017, 06:24 PM   #10
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Re: D1SC build

Thanks man, I've definitely been taking it easy and staying well away from 6000 rpms.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-17-2017, 12:14 PM   #11
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Re: D1SC build

Great build, awesome numbers...congrats and enjoy !!!!!
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2003 DSG Mach 1-03 Cobra Term/T56 swap:
2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
Tuned by B.Kurgan
601Hp/558/Tq
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Old 10-26-2017, 02:38 PM   #12
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Re: D1SC build

Thanks man, I'm definitely enjoying it!

Quick question, I have the big Red Race bypass valve vented to atmosphere currently and it sounds like a rattlesnake when I shift after the boost has built up, usually anything higher than 4k rpm. is the bypass valve supposed to sound like that? when I was on the dyno it was recirculated and you could barely hear it after a 5k rpm shift. I'm assuming maybe the 1.25" tube the air is passing through is restrictive and it's having trouble forcing the extra boost out of that size hole. I just want to be sure it's not compressor surge. the car doesn't act weird or anything, so I don't think it's anything bad but I can't find any videos on youtube that sound like mine does.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-26-2017, 03:50 PM   #13
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Re: D1SC build

my recirculating BRRV does not do that - mine is vented to atmosphere with nothing attached. I just get a nice loud, clean blow off

that being said - does yours have a high pitched howling type sound in the 2k rpm area?

If not I would be curious for both of us to compare how the adjusting nut/rod on the top of the valve is set. That sound makes me wanna swerve into oncoming traffic.
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Old 10-27-2017, 04:18 PM   #14
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Re: D1SC build

I haven't tried playing with any adjustments on the bypass valve, most of the stuff I read said not to. the vacuum line for it is coming straight from the intake manifold where the driver side PCV hose went. Had to put a bunch of reducers in to get the size of the hose down to what it needed to be. I did try it without the hose attached at all, but that was to visibly make sure the valve was working and I can't remember if it made the rattlesnake sound when I had it running that way, might not have revved it that high. It sounds badass, I'd just like the peace of mind that it's working properly.

I don't think I have a high pitched howling sound around 2k. Where is your bypass valve pointed? Maybe it's blowing into something that's making a noise with just the right amount of flow, like a flute. my exhaust is pretty loud though, from inside the car I can't even hear the constant woosh that the bypass valve makes at idle/cruise. my passengers say they can hear it, and I can hear it from outside the car.

I'm going to try running it without the hose attached again and see if it still makes the rattlesnake noise. If it doesn't, then it's probably just how the air is passing through that hose.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-27-2017, 05:14 PM   #15
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Re: D1SC build

Solved it, the hose had managed to wedge itself between the A/C lines, almost closing the passage. with the hose disconnected I could not reproduce the rattlesnake sound, nor could I get it to do it with simply putting the hose back on. Once I tried folding the hose over a bit though, it did it right away.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-27-2017, 09:27 PM   #16
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Re: D1SC build

Glad it was an easy fix. My outlet points down to the ground at the same angle as the first discharge pipe. Not blowing into anything, ended up putting a radiator hose on to direct into the wheel well which helped but still super loud. If your car is where you can take a pic of the adjuster I’d appreciate it. I’ve got my vacuum source from a port I tapped into the EGR delete plate
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Old 10-28-2017, 08:39 PM   #17
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Re: D1SC build



here's a close up of it. After winter I might try a different hose and route it better, my opening points right up past the blower to the power pipe, but I could point it the other way and direct the air into the driver side fender.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-29-2017, 09:04 AM   #18
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Re: D1SC build

Go with a Tial Q50...it is by spring, uses a green for ProCharger application..no fuss, great sound.
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2003 DSG Mach 1-03 Cobra Term/T56 swap:
2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
Tuned by B.Kurgan
601Hp/558/Tq
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Old 10-29-2017, 11:12 AM   #19
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Re: D1SC build

Quote:
Originally Posted by not a gt View Post
Go with a Tial Q50...it is by spring, uses a green for ProCharger application..no fuss, great sound.
How much boost is it good for though? I知 at 15 now and if I max the D1 would be around 20. I知 gonna fiddle with this valve some before buying something else and having to change flanges again. I know running 2 smaller valves is also an option

The valve above either has had the adjuster screw cut short or its adjusted further in than mine. I値l get pics later
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Old 10-29-2017, 01:02 PM   #20
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Re: D1SC build

The Tial does sound great in the vids I've found. Gotta save the money for now though, need cams and a built transmission before I can swap the built engine in there . My main concern is that the one I have is working correctly, and it seems to be the case now that I have returned the hose to its original recirculating function. Now I'm a little curious if the previous owner of this bypass valve did any adjustment to it though.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 10-29-2017, 06:38 PM   #21
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Re: D1SC build

Quote:
Originally Posted by DSG2003Mach1 View Post
How much boost is it good for though? I知 at 15 now and if I max the D1 would be around 20. I知 gonna fiddle with this valve some before buying something else and having to change flanges again. I know running 2 smaller valves is also an option

The valve above either has had the adjuster screw cut short or its adjusted further in than mine. I値l get pics later
Not sure, got to be pretty high boost level for some of applications I seen it on, I want to guess maybe that is what different sprung rates are for?? Others should chime in soon, good to see you guys still on here, once I get computer going will update build..lots have went on lol. From what I have read once you start playing with that adjudter, never seems to work tight again, they must be really finicky.
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2003 DSG Mach 1-03 Cobra Term/T56 swap:
2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
Tuned by B.Kurgan
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Old 11-10-2017, 11:13 AM   #22
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Re: D1SC build

Question related to the build, at what power/torque level will I want to upgrade my exhaust system from 2.5" to 3"? I love how my current setup sounds, but the ceramic coating on the headers is peeling and starting to rust (surprisingly the rest of the exhaust isn't rusting at all and it's made of aluminized steel). Since I'm planning to do the engine swap next year, if I'm going to upgrade the headers in the near future, that would be the time to do it I'm thinking. I'm sure the headers aren't rusted all the way through yet, . What do you guys think?
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 11-10-2017, 11:47 AM   #23
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Re: D1SC build

from everything Ive seen there would be no need to upgrade. My motor was built with 25psi max and I was told my exhaust should be fine and even to save my money and not port the heads. If it were gonna be an actual race car or grudge car that might change things.

theres been a few threads on this, I believe on SVTP or Modular Fords and in the NA SVT facebook page
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Old 11-10-2017, 12:07 PM   #24
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Re: D1SC build

Ya I'm looking through some of those threads now, I'll just have to gauge how bad the rust is getting before I do the swap. It might just be surface rust and me being paranoid.
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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Old 01-16-2018, 09:01 AM   #25
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Re: D1SC build

Does anyone have a way of estimating boost based on the pulley size?I know there are more factors than that, I'm trying to figure out which cams I'm going to buy to replace these turbo cams in my built long block. I'm looking at the Modular Head Shop 4v blower cams stage 2 and stage 2.5.
http://www.modularheadshop.com/i-307...tegory:1404149
http://www.modularheadshop.com/i-307...tegory:1404149

I have 2 other pulleys at my disposal right now, a 3.8" and a 3.2". I don't want to go overboard right away, but while I'm swapping out the old engine for the built one, I might as well install the 3.8 pulley so I don't have to spend more money on another tune down the road (and also I won't have to grind down the valve cover on the new engine for the pulley to fit). Neither the stage 2 or 2.5 sound like they're so hardcore that I can't drive it on the street, so it comes down to how much boost I'll make with either of these pulleys. the stage 2 cams say they're good until 16 lbs of boost, and the 2.5 say they're good for 20 lbs. Currently I'm making 8.9 at 6100 rpms with the 4.15" pulley. with the built engine I should be able to rev to 6800-7000 with no issues. My thoughts are that if I'm never going to break 16psi of boost with the smallest pulley I have, then there's no reason to get the stage 2.5 cams.

Here is the list of stuff in the built engine if that helps:
Teksid Block .020 Over
DSS Forged Rods
DSS Forged Pistons(9.5 Compression)
DSS Main Support Girdle
Kellogg 5.0 Stroker Crank
All ARP Hardware
Moroso Oil Pan
Melling Billet Gear Oil Pump
Commetic Head Gaksets
ARP Head Studs
2004 4V Heads: 9 thread, revised cooling, ect
Extreme Duty Valve Seals
Bronze Valve Guides
Ferrea SS Valves and Followers
MHS Stage 3 Mid Lift Turbo Cam
MHS Stage 2 Valve Springs
Cooling mod
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Black 2003 Mach 1, Melanie, 483hp/451tq @6100, 8.9lbs
-Stock longblock, stock transmission, Procharger D1SC 4.15" pulley, Accufab 60mm TB, P/P intake manifold, full MAC exhaust, return style fuel system, Maximum Motorsports/Steeda suspension, Torsen T2R 31 spline diff, Mickey Thompson SC-5 18" with Nittos.

Red 2007 Focus ST, daily driver
-FRPP shocks & struts, spec racing springs, SVT wheels, Cosworth intake manifold, FSWerks CAI, Stealth exhaust, tune and strut bars.
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