Turbosmart Cat2005.indd

Company Profile
The Turbosmart brand is about to launch into another decade of producing turbo accessories that are second to none. Our focus on product developement and innovation is
stronger than ever. The coming years will see this intensify as we expand into new and
exciting product ranges.
Our aim is to provide a quality and high performance product that is easy to operate.
These qualities are evident accross our range and have driven our success. We go to great
lengths to ensure our products are manufactured to the highest standards. From the latest in multi axis CNC equipment to our dust free temperature controlled assembly area,
we strive to achieve microscopic precision to ensure that our hand picked products are
of superior quality.
Through the tireless efforts and passion of our dedicated team, the Turbosmart watermark can now be seen all over the world. Our products appear in over fifty countries and
are proudly supported by over a thousand authorized outlets. By embracing new technology we will continue to strengthen our presence in the world market and remain at
the forefront of this growing market.
Our focus on the customer, quality and performance will ensure our further expansion
into new product areas. As we look towards an even brighter future these factors will
ensure that the Turbosmart DNA of Style, Performance and Functionality, will remain.
NEW Sleeper Series
The Sleeper Series is a new colour range of Turbosmart products intended to
appeal to those who require performance that blends into their engine bay.
The Sleeper Series is bound to attract less attention without compromising the
benefits of Turbosmart products.
Sleeper
Series
Contact our team for more details
16
2
Contents
NEWTS
Sleeper Series...................................................... 2
PRODUC
Blow-off valves
Introduction............................................................. 4
Multi-fit BOV’s.......................................................... 5
Model specific BOV’s................................................ 6
Kompact BOV’s......................................................... 7
Fitment Guide........................................................... 8-9
BOV Adapter kits-Model specific........................... 10-11
BOV Adapter Kits-Universal.................................... 12
New 60mm e-Boost... Page15
Boost Controllers
Introduction............................................................. 13
Gated boost controllers.......................................... 14
e-Boost..................................................................... 15
Fuel Cut Defenders
Fuel cut defenders................................................... 16
Fitment Guide........................................................... 17
New
Wastegates
Series... Page 7
Introduction ............................................................ 18
Ultragate 38 ............................................................. 19
Progate 48 ................................................................ 20
Promotional Products....................................... 21
BOV Adapter Kits... Page 10
Research & Development................................ 22
Warranty................................................................ 23
COMING
SOON
Turbosmart Pty Limited has made every effort to include the most accurate and up to date information
in this catalogue, at the time of printing. Turbosmart Pty Limited will not be held responsible for any
errors, or omissions and reserves the right to make changes without notice.
ULTRA-GATE
EXTREME STREET
HORSEPOWER
BOV
Kiwi RE
Alec Bell’s Pro import RX2 is soon to
debut on the NZ Drag scene with its 3
Rotor PP twin turbo engine using two
Pro-gate 48s and a Megasonic BOV.
EXTREME
HORSEPOWER
WASTEGATE
17
3
Blow-off Valves
INTRODUCTION
Why do you need a blow off valve?
To eliminate compressor surge when changing gears. Excessive back pressure
is created when the throttle is closed during gear changes or deceleration,
causing turbo cavitation. This is detrimental to the life of your turbocharger,
however fitting a BOV will substantially improve this problem.
By installing a BOV you will significantly reduce turbo spool up time. You will
notice a substantial improvement in response from your turbo between
gearshifts. Boost will come on earlier giving an increase in torque at lower RPM.
How much boost will it hold?
With pressure acting equally on
both sides of the piston it will hold
unlimited boost.
Selecting the right BOV is essential
Here are the reasons why:
ADJUSTMENTS
Access to your BOV once it is fitted may be difficult, therefore
adjustment must be straight forward and require no tools
Adjustable by hand
Tools required
FLOW
The BOV must flow enough to eliminate compressor surge. This
helps boost response between gear changes intern reducing wear
and possibly a bearing failure in you Turbocharger.
VALVE SEAT
Large ports for quick response
and high boost applications
Small inlet
Plastic seat unreliable at
high temperatures.
Piston retained by
non-secure circlip
The BOV must have solid construction
to handle the thousands of cycles it
will see during the years of use.
An inferior seating system will
eventually fail and drop foreign
material into your engine
CONVERSIONS
Intergrated Billet seat
eliminates debris from
component failure
Certain BOV’s in our
range can be
reconfigured to suit
your current
needs.
Wayne Dyson from Dyson Rotary
steers his Pro-Gate 48 equipped 20B RX3
to run a best of 8.540 @ 154.8 mph
on only a 28x 9 inch slick and is now the
Andra Sport Compact OZ Mod national record holder.
4
ADAPTER SYSTEMS
The BOV must have an
adapter kit that is well
thought through,
and is supplied with all
necessary hardware.
Blow-off Valves
Availab
le in
Sleeper
Series
MULTI-FIT BLOW-OFF VALVES
One of the many innovative features of a Turbosmart BOV is the Multi-Fit adapter system. This system was developed by Turbosmart to make the important job
of fitting a BOV, a simple routine. The Multi-Fit adapter system is best described
as a plug and socket arrangement. In the base of each BOV is the socket. The
correct adapter slides into the socket or base of the BOV and connects the BOV
to the adapter. The adapter is locked in place by three stainless steel grub
screws with lock nuts and is sealed tight by an O-ring.
BOV TYPE 1
P/N:
FG-BOV-001
The Type 1 BOV is best suited to engines up to 1.5
litres in capacity, producing standard or mildly
increased boost.
VEE PORT
P/N: FG-BOV-002VP
Features the unique variable exhaust port
system, resulting in superior venting of excess
pressure, a popular choice for the street.
PLUMB BACK
P/N:
P/N:
P/N:
P/N:
P/N:
FG-BOV-003PB25
FG-BOV-003PB29
FG-BOV-003PB32
FG-BOV-003PB34
FG-BOV-003PB38
25mm outlet
29mm outlet
32mm outlet
34mm outlet
38mm outlet
For the serious enthusiast NOT wanting to be noticed, the Plumb Back BOV allows all pressure to be
vented back into the intake system.
DUAL PORT
P/N:
P/N:
P/N:
P/N:
P/N:
FG-BOV-003DP25
FG-BOV-003DP29
FG-BOV-003DP32
FG-BOV-003DP34
FG-BOV-003DP38
25mm outlet
29mm outlet
32mm outlet
34mm outlet
38mm outlet
A BOV that will vent to atmosphere and back into
the air intake. Dual ports with sequential timing
allow quieter operation during normal driving
loads with the benefit of a Supersonic during
race conditions. Supplied with parts to convert
between Plumb Back and Supersonic.
SUPERSONIC
P/N:
FG-BOV-003SS
For the serious racer wanting to be NOTICED. Widely
used in both the show and race scene worldwide.
MEGASONIC
P/N:
FG-BOV-003MS
This BOV is now the highest flowing in our range,
out flowing most BOV’s available, ideal for the
serious racer. It also caters for the show cars
that wish to stand out from the crowd.
5
Blow-off Valves
MODEL SPECIFIC BLOW-OFF VALVES
Availab
The following range of BOV’s are designed specifically for applications where space or
other constraints will not allow for a Multi-Fit BOV to be used. They are supplied as bolt
on kits, complete with everything required to fit the BOV.
le in
Sleeper
Series
Subaru WRX 2001-2005
Shown with
factory BOV
outlet
Vee Port
P/N: FG-BOV-WRXVP
P/N:
Plumb Back
FG-BOV-WRXPB
P/N:
Dual Port
FG-BOV-WRXDP
P/N:
Supersonic
FG-BOV-WRXSS
Subaru Liberty GT
Plumb Back
P/N:
FG-BOV-LBGTPB
Johnston Research and
Performance
Dual Port
Supersonic
P/N:
P/N:
FG-BOV-LBGTDP
FG-BOV-LBGTSS
02 WRX as featured in Performance Auto
& Sound and seen at the 2003 SEMA Show
Las Vegas fitted with an e-Boost and
Supersonic BOV
Mitsubishi EVO VI, VII, VIII
Dual Port
P/N:
FG-BOV-EVODP
Carl Vaughan Motorsport
6
Mitsubishi Lancer EVO
Fitted with an Ultra-Gate 38, Plumb Back BOV
and In Cabin Gated Boost controller.
2004 NZ clubsport champion
2004 NZ autocross champion
2nd in 2004 NZ hillclimb championship
And multiple current hill climb record holder
Blow-off Valves
INTRODUCING THE BRAND NEW
SERIES
A replacement blow off valve for any vehicle using plastic Bosch or Denso BOV. The ‘Kompact’ range has been designed and
engineered as a high flow drop in replacement for most European cars and even our own Aussie XR6 turbo and Mazda
MX5 SE turbo. All Kompacts come with appropriate hoses, clamps and fittings to install in most vehicles.
For specific instructions for your vehicle please visit our website.
Plumb Back
Factory fitted
plastic BOV
P/N:
P/N:
FG-BOV-KTPB25
FG-BOV-KTPB20
Supersonic
P/N:
P/N:
FG-BOV-KTSS25
FG-BOV-KTSS20
Dual Port
P/N:
P/N:
FG-BOV-KTDP25
FG-BOV-KTDP20
Kompact BOVs avaialable in 25mm and 20mm inlet and oulet ports.
European performance just got a whole lot easier!
Audi 2.7 litre V6 Twin Turbo
Part No:
FG-BOV-KTDPV6
Suppied complete to
fit a V6 Audi, including
comprehensive pictorial
instructions.
Before
After
7
Blow-off Valves
BLOW-OFF VALVE FITMENT GUIDE
Staggs Racing
Fastest VW powered
altered in the world
using a Dual Stage
Gated Boost
Controller to run
a best of
7.90 @ 165 mph
Easy Street Motorsports, Inc.
8
The Worlds Fastest Street Subaru
9.44 @ 149.5 mph on radials
using a Turbosmart e-Boost!
Blow-off Valves
BLOW-OFF VALVE FITMENT GUIDE Cont...
These tables contain Turbosmart’s recommendations for Blow-off Valve selection and is to be used as a guide only. These
recommendations are to ensure a straight forward installation based on the engine being in or close to standard trim. Due to
space constraints larger BOV’s, although better suited, have not been recommended for some models.
The Nitrous Express RX7
Fitted with a Pro-Gate 48 and
Megasonic BOV as featured
in Super Street,
Car Tuning Mexico,
Performance
Auto & Sound
and Redline
Magazine.
AET Engineering Ltd.
Andy Nicholls from AET Engineering Ltd is responsible for this
500hp MG Maestro Turbo. A Progate 48, e-Boost and Megasonic
BOV combine for a best of 11.96 @ 130mph making this the UK’s
fastest FWD car.
Titles include the Ultimate street car since 1999 and the quickest
FWD at the Ten of The Best I, II & III
9
Blow-off Valves
ADAPTERS Model Specific
An important aspect that is often overlooked when purchasing a Blow-off Valve is fitting the BOV to your vehicle. This can be
costly and time consuming as special parts may need to be fabricated. A poorly made adapter may cause serious damage to
the BOV and engine. At Turbosmart we provide the complete solution. We have a comprehensive range of Model specific
adapters designed to fit directly to your vehicle.
Please refer to the Blow-off Valve Fitment Guide in this catalogue for a
complete listing of makes and models.
Nissan 200SX, S14 & S15
Daihatsu COPEN
Adapter Kit
P/N: FG-ADM-COPEN
Pipe Kit P/N: FG-ADM-200SX
Mitsubishi Eclipse Gen 2
Adapter Kit (USA & Canada Only)
P/N: FG-ADM-ECL2
Mitsubishi 3000GT
Ford XR6 Turbo
Pipe Kit
P/N: FG-ADM-XR6
Adapter Kit
P/N: FG-ADM-3000GT
Mitsubishi Eclipse Gen1
Adapter Kit
(USA & Canada Only)
P/N: FG-ADM-ECL1
Nissan Pulsar GTI-R
Adapter Kit
P/N: FG-ADM-GTIR
Nissan R32 SKYLINE GTS-t
Holden Astra
Pipe Kit
P/N: FG-ADM-ASTRA
Plumb Back Connection Kit
P/N: FG-ADM-200SXPBK
Nissan 180SX-S13, CA18
Pipe Kit
P/N: FG-ADM-180SXCA
BOV Adapter Kit
P/N: FG-ADM-R32
Plumb Back Connection Kit
P/N: FG-ADM-R32PBK
Nissan 180SX-S13, SR20
Pipe Kit
P/N: FG-ADM-180SXSR
Nissan R33 SKYLINE GTS-t
BOV Adapter Kit P/N: FG-ADM-R33
Plumb Back Connection Kit
P/N: FG-ADM-R33PBK
10
Blow-off Valves
ADAPTERS Model Specific cont...
Subaru Liberty/Legacy
Adapter Kit
NISSAN 300ZX TT
P/N: FG-ADM-LIBRS
Adapter Kit
P/N: FG-ADM-300ZX
Smart-Fortwo & Roadster
Pipe Kit
P/N: FG-ADM-SMART
Subaru Forester GT 01’/02’
2.0 Litre Adapter Kit
P/N: FG-ADM-FRST20
Toyota MR2
Adapter Kit
P/N: FG-ADM-MR2
Subaru Liberty/Legacy B4 (BE5)
Twin Turbo 02’/03’ Adapter Kit
P/N: FG-ADM-LBB4
Toyota Soarer 2.5TT
Pipe Kit
P/N: FG-ADM-SOARER
Subaru WRX 99’/00’
Adapter Kit
P/N: FG-ADM-MY99
Toyota Supra JZA80
Pipe Kit
P/N: FG-ADM-SUPRA
Subaru WRX 97’/98’
Subaru Forester XT 03’/04’
2.5 Litre Adapter Kit
P/N: FG-ADM-FRST25
Adapter Kit
P/N: FG-ADM-MY98
Toyota Starlet
Adapter Kit
P/N: FG-ADM-STAR
Robert Barac’s
APC tuned EVO
Lancer is the fastest in
Australia with its 4G63
boasting two
Supersonic BOV’s and
an e-Boost for its best
run of 9.97 @ 145.35
mph!
Tony Rigolli Performance
Fastest Subaru WRX in the world running a
8.88 @ 154 mph using a Turbosmart e-Boost.
11
Blow-off Valves
ADAPTERS Universal
We have a comprehensive range of Multi-Fit adapters designed to fit directly to your vehicle. Please refer to the Fitment Guide
in this catalogue for a complete listing of makes and models.
Hose Adapters
Hose Adapter -suit 19mm ID hose
Hose Adapter -suit 25mm ID hose
Hose Adapter -suit 32mm ID hose
Hose Adapter -suit 34mm ID hose
Hose Adapter -suit 38mm ID hose
P/N: FG-ADA-HO19
P/N: FG-ADA-HO25
P/N: FG-ADA-HO32
P/N: FG-ADA-HO34
P/N: FG-ADA-HO38
supplied with
corresponding blank
Hose Tee Adapters
Hose Tee Adapter -suit 2.0” ID hose P/N: FG-ADA-HT200
Hose Tee Adapter -suit 2.5” ID hose P/N: FG-ADA-HT250
Hose Tee Adapter -suit 3.0” ID hose P/N: FG-ADA-HT300
Blanking Plugs
19mm ID Hose Blanking Plug
25mm ID Hose Blanking Plug
29mm ID Hose Blanking Plug
32mm ID Hose Blanking Plug
34mm ID Hose Blanking Plug
38mm ID Hose Blanking Plug
P/N: FG-ADA-BLNK19
P/N: FG-ADA-BLNK25
P/N: FG-ADA-BLNK29
P/N: FG-ADA-BLNK32
P/N: FG-ADA-BLNK34
P/N: FG-ADA-BLNK38
Miscellaneous
Adapters
HKS SSQ Adapter
fits to existing flanges.
P/N: FG-ADA-HKS-SSQ
Greddy Type S & R Adapter
fits to existing flanges.
P/N: FG-ADA-GREDDY
Weld-on Stainless Steel
adapter as supplied with
all Multi-Fit BOV’s.
P/N: FG-ADA-SS38
Weld-on
Aluminium adapter
P/N: FG-ADA-WA38
Dave McPherson pilots his 13B powered
KE20 Toyota Corolla, complete with Pro-Gate 48,
Megasonic BOV and e-Boost for an astounding
8.542 @ 161.1 mph on a tiny 28x9 inch slick,
making this the fastest un-tubbed rotary
powered car in the world!
12
BOV adapter block off cap
suits all Turbosmart BOV adaptors.
P/N: FG-ADA-CAP
Universal 90 degree
elbow adapter
P/N: FG-ADA-UELB
AET Turbo’s Grant Parker has
built this fully road legal Golf GTI fitted
with a 20-valve 5-cyl Audi Quattro
all-wheel drive engine & driveline
package that develops over 700 hp
via its radical turbo setup. Using a
Megasonic BOV, Pro-Gate 48, e-Boost
and aided by a shot of nitrous, the
4wd Golf has achieved a 10.6 E.T on
road tires making it the
fastest Golf in the world!
This little green monster
also claims a long list of
titles including Top 10
finishes in the 03 & 04
Ten of the Best and
overall winner of GTI
International 2004.
Weld-on Stainless
Steel 90 degree elbow
adapter
P/N: FG-ADA-SELB
Boost Controllers
INTRDUCTION
How a boost controller works
A turbocharger uses waste exhaust gases and the energy associated with this gas to
drive a turbine located after the exhaust manifold. The exhaust gases drive the turbine
wheel that in turn spins the compressor wheel compressing the intake air and forcing it
into the intake creating boost pressure.
To limit the amount of pressure or boost generated by the compressor most turbo
chargers are fitted with an internal wastegate. The wastegate is comprised of a
wastegate actuator which is a spring-loaded diaphragm and a wastegate valve or flap.
Changing the spring tension in the wastegate actuator can vary the boost pressure.
However this method of controlling the maximum boost pressure allows for only fixed
changes in boost pressure.
Instead of changing the springs, a more effective method of adjusting boost is to alter
the amount of pressure to the wastegate. A Gated Boost Control Valve or an Electronic
Boost controller is a controlled leak of boost pressure to the wastegate actuator.
For example if normally the wastegate opens at 9psi but a boost pressure
of 12psi is desired, a leak of 3psi would be vented so that at 12psi boost
pressure the actuator sees only 9psi and starts to open.
Connecting a boost controller
Gated Boost Control Valve
connected to an
internal wastegate
Gated Boost Control
Valve connected to
an internal wastegate
for Twin Turbos
Gated Boost Control
Valve connected to
an external
wastegate
e-Boost Controller
connected to an
external wastegate
e-Boost Controller
connected to an
internal wastegate
Online Performance’s
Honda CRX/Del Sol uses a Megasonic BOV and an e-Boost that is
setup to increase boost pressure in higher gears when more traction is available. With a best of 9.07 @ 158 mph this is the fastest
FWD in Australia!
Rod Penrose pilots his Bug mostly on its back two
wheels to claim the title of the fastest VW in Australia
using two Ultra-Gate 38s and an e-Boost for a P.B. of
8.96 @ 161mph.
13
Boost Controllers
Availab
le in
Sleeper
Series
Gated Boost Controllers
Constructed from high grade brass and aluminium, these boost controllers are renown
for their easy installation, user friendly accurate adjustment and most of all stable control.
Boost Tee
In Cabin
P/N: FG-GBCV-BT
• Set your boost and forget it
• Boost is fully adjustable from
under the bonnet
• Detent System for ease of
adjustment
• Gated System to bring boost
on faster
• Supplied with billet
mounting bracket
P/N: FG-GBCV-IC
Designed to be mounted inside
the cabin and allows for boost
adjustment on the run. Ideal
for the active enthusiast.
• Control boost from the
drivers seat
• Detent System for ease of
adjustment
• Gated System to bring boost on faster
• Mounting bracket, hose and all fitting
hardware supplied
Single Stage
P/N:
FG-GBCV-SS
This unit provides fast boost response with one
adjustable boost level. Ideal for turbo cars without
factory boost controllers. Switch between standard
and high boost.
• High boost setting is fully adjustable
• Detent System for ease of adjustment
• Gated System to bring boost on faster
• Includes Rocket Launcher Switch, mounting bracket
and fitting hardware
Dual Stage
P/N: FG-GBCV-DS
This unit provides fast boost response with two adjustable
boost levels. Just toggle between high and low on the fly.
Ideal for replacing factory boost controllers.
• Low and high boost settings are fully adjustable
• Detent System for ease of adjustment
• Gated System to bring boost on faster
• Includes Rocket Launcher Switch, mounting bracket
and fitting hardware
Accessories & Spares
Boost Controller Fitting Kit
P/N: FG-GBS-FK-*
This kit includes everything required to install a boost
controller to an engine
• Suited to all Turbosmart Boost Controllers
• Please specify hose colour * RD=RED, BL=BLUE, BK=BLACK
Twin Turbo Fitting Kit
P/N: FG-GBS-TTK-*
This kit allows for two wastegates to be connected to any one Turbosmart
Boost Controller.
• For parallel twin turbos only – not suited to sequential turbo applications
• Please specify hose colour * RD=RED, BL=BLUE, BK=BLACK
14
Rocket Launcher Switch
p/n: FG-PA-RLS
Boost Controllers
e-Boost
NEW
ction for Sport Compact
tru
ns
Co
60mm
The e-Boost electronic boost management system is the culmination of many years
of research, development and innovation, with countless hours spent testing on
the dyno, the race track and the drag strip. The e-Boost is more than just the best
performing electronic boost controller, it is a complete boost management system,
making Turbosmart a world leader in boost control systems. This revolutionary
product is loaded with features, squeezed into a package small enough to fit in the
palm of your hand.
• Available 60mm and 66mm Diameters in 40 & 60 PSI
FG-EBOOST-406BK........40 PSI MAX Boost - Black 60mm eboost
FG-EBOOST-606BK........60 PSI MAX Boost - Black 60mm eboost
FG-EBOOST-406WT.......40 PSI MAX Boost - White 60mm eboost
P/N: FG-EBOOST-406BK
FG-EBOOST-606WT.......60 PSI MAX Boost - White 60mm eboost
FG-EBOOST-40SL..........40 PSI MAX Boost - Silver 66mm eboost
FG-EBOOST-60SL..........60 PSI MAX Boost - Silver 66mm eboost
60mm
Shown with optional
shift/warning light
NEW Features & specifications:
• Six individually programmable boost set points - internally or
externally activated
• Sequential set point option
• RPM shift/warning light output
• Clamp on shift light option - available on 60mm versions only
• Advanced short circuit protection
• Boost mapping-rpm compensation
Features & specifications:
• The latest in Hi-tech electronics resulting in fast and smooth
boost response
• Utilising the latest in surface mount technology – light and ultra compact
• Gauge type construction allows many practical mounting solutions in
66mm (2 5/8”) and 60mm
• Suitable for panel mounting, gauge pod or pillar mounting systems
• Electronics are housed in a billet aluminium housing offering durability
in harsh race conditions
• Programmable gate pressure function to eliminate wastegate creep
• Drag racers - improve your launch, run a different boost in each gear
• High accuracy boost and vacuum display, readout accurate
to within +/- 0.5% of full scale, boost gauge no longer required
• Display can be configured in KPA, Bar or PSI
• Easy to read seven segment display with programmable bar graph
• Programmable auxiliary output – e.g. water spray control, water/methanol
injection/nitrous control
• Programmable audible warning alarm – excellent for
over-boost warning or full boost confirmation
• Peak hold/Max Boost recall function
P/N: FG-EBOOST-406WT
P/N: FG-EBOOST-40SL
TURBOSMART SOLENOID
• Short stroke solenoid produces high energization shifting force
• High force return spring due to high force solenoid, maximizes
both energization and de-energization shifting forces
• Built-in wear compensation - valve stroke is shorter than solenoid stroke
Short stroke = High force = Valves that don’t stick
Accessories & Spares
e-Boost shift/warning light - suit 60mm e-Boost only FG-EBC-60WL01
e-Boost twin shift/warning light - suit 60mm e-Boost only FG-EBC-60WL02
Mounting Pod 66mm -Black FG-PA-GAU3202
Pac Performance on e-Boost
Rocky Rehayem talks about e-Boost :
FG-EBC-60WL01
FG-EBC-60WL02
Q- How well does the e-Boost perform?
“The boost curve with the right wategate, and the right spring will be horizontal”
Q- How does a horizontal boost curve relate to your performance on the race track?
“The less spike and drop off in boost the faster the car is” (MX6)
Q- How complicated is the e-Boost to set up on a car?
“The first time I used an e-Boost I read the instructions once and then tuned the car”
15
Fuel Cut Defenders
Do you need a Fuel Cut Defender?
• Most late model turbo systems have inbuilt defence mechanisms to guard against increases in boost pressure.
Such systems are important, but are an obstacle when increasing boost pressure.
• A Turbosmart FCD will allow boost pressure to be increased above the factory fuel cut and prevent momentary
shutdown of the fuel injection system.
• Turbosmart FCD’s increase or remove the fuel cut out level, depending on the model selected
• Increasing boost pressure is often the most cost effective increase in horsepower
Pneumatic Fuel Cut Defender
P/N:
FG-FCD-001
Accurately increase the factory fuel cut out when increasing boost pressure,
no cutting or splicing wires.
• Suited to most turbo cars that use a MAP sensor to determine the fuel cut level
• Allows you to increase the factory fuel cut, without effecting off boost conditions
• Can be locked to prevent tampering
• To be used in conjunction with a Turbosmart Boost Controller
Electronic Fuel Cut Defender
P/N: FG-FCD-002
Accurately eliminate the factory fuel cut out when increasing boost pressure.
• Features simple adjustment with L.E.D. indicator for easy set-up
• This FCD has a compact water-resistant housing
• Suitable for under hood or incar installation
• To be used in conjunction with a Turbosmart Boost Controller
Electronic Fuel Cut Defender
P/N:
FG-FCD-002S
Suits Nissan Skyline R32 and 300ZX
Accurately eliminate the factory fuel cut out when increasing boost pressure.
• Features simple adjustment
• This FCD has a compact housing for under dash installation only
• To be used in conjunction with a Turbosmart Boost Controller
Caution: Turbosmart strongly recommends to check the air / fuel ratio when a Fuel Cut Defender is installed. Once an FCD is ins
not to increase boost pressure beyond the engines capability. Failure to observe this caution may result in severe engine damage.
The quickest FWD import in
Canada is Paul Bhawan’s unibody Honda
Civic and it claims the titles of the fastest
sport compact in Canada, the CSCS 2003 Pro 8
Champion and the ISDS Champion!
The Civic uses the package of a Megasonic
BOV, a Pro-Gate 48 and an e-Boost that all
help this little blue rocket achieve a record
ET of 8.66 @ 166mph.
16
Fuel Cut Defenders
FUEL CUT DEFENDER FITMENT GUIDE
Connecting an electronic
fuel cut defender
Malvin from Turbo Tech in Puerto Rico uses a mix of
Turbosmart products on his wild creations including drag cars,
Jet skis and his speciality turbocharged quad bikes!
17
Wastegates
INTRODUCTION
Why use a Turbosmart wastegate?
Turbosmart wastegates feature innovative design, engineering and the finest materials available. These are traits that over recent years Turbosmart has become renown for
making a Turbosmart wastegate an obvious choice. The wastegates body is investment cast
from 253MA Stainless Steel (ASTM S30815). This grade of stainless steel has high strength
and excellent resistance to oxidisation, creep deformation and wear, but most
importantly is right at home in temperatures beyond 1200C (2192F). The diaphragm
housings are billet 6262 T6 Aluminium, coupled with 17-7PH springs and Silicone Nomex
reinforced diaphragms. Turbosmart wastegates have been subjected to our extreme
development and testing procedures, however what’s important is that we have countless
wastegates on race engines winning races.
Will a Turbosmart wastegate do the job?
Key design features to a superior wastegate are temperature and flow capability. Turbosmart has successfully addressed these
issues by optimising valve lift and the flow path through the body. We have incorporated the unique temperature isolation
zone, and utilised the most exotic alloys available. In fact we guarantee to beat the performance of any other wastegate of an
equivalent size! All these features ensure our wastegates survive incredible temperatures and a lifetime of punishment.
Selecting the right Wastegate is essential
Things to check for:
• FLOW
• VALVE CONSTRUCTION
The valve needs to be constructed in one piece to handle
extreme temperatures. Valve material choice is
critical to avoid failure at high temperature.
High valve lift and well designed flow path are key
features to achieving superior efficiency.
Commonly used
two-piece welded valve
High strength one-piece
billet valve construction
High lift valve ensures superior flow
• DIAPHRAGM MATERIAL
It is important that the diaphragm is able to withstand
high temperatures and thousands of cycles.
High Temperature Silicone Nomex
Insufficient valve lift causes boost creep
• SPARE PARTS
Turbosmart support their wastegates with a
full range of spares
Inferior material can cause over-boost
• ADAPTER SYSTEMS
TURBOSMART have a large range of spare parts
A simple and reusable adapter system is
essential for quick and easy installation to a
pre-existing or factory
turbo system.
TURBOSMART supplies a range of adapters to suit
many applications
From Pac Performance
Rocky Rehayem talks about wastegates :
Q- Why did you start using Turbosmart Wastegates?
“Turbosmart wastegates come with all the parts needed for an
install including all the different springs which is unlike other
brands”
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Robert Campisi’s Ford Cortina sports a HRD tuned
twin turbo 406 cube windsor running two Pro-gate 48s and
two Supersonic BOV’s to give over 1200hp at the flywheel,
enough to run a 7.83 @ 170 mph on the track.
Wastegates
ULTRA-GATE 38
38mm Wastegate
P/N:
FG-WGATE-38
Ultra compact, Ultra flow!
The most compact 38mm wastegate on the market, featuring the common two
bolt flange design used by many turbo kit manufacturers. The Ultra-Gate’s design
incorporates a unique temperature isolation zone to reduce heat transfer to the
diaphragm, a true 35mm inlet port for maximum flow, an investment cast stainless
steel body and one-piece billet valve for strength and reliability. We have
successfully used Ultra-Gate 38s on engines producing up to 600HP.
• Ultra compact overall height, 112mm (4-1/2 inch) and 100mm across (4 inch)
• Silicone Nomex diaphragm - durability under extreme temperatures and stress
• Optimum actuator to valve ratio for precise boost control
• Superior body design and huge valve lift ensure unrivaled flow
• Supplied with weld on steel manifold flanges, gaskets and
springs to give 7, 10, 14 and 17psi.
• Fully compatible with all Turbosmart Boost Controllers
Accessories
Garrett 32 to Ultra-Gate adapter ..................................P/N: FG-WG38-AGRT
KKK (Small) to Ultra-Gate adapter ................................P/N: FG-WG38-AKKK
Spring 3 psi outer -Light Blue ........................................P/N: FG-WG38-SP03
Spring 5 psi outer -Grey .................................................P/N: FG-WG38-SP05
Valve Locking Tool -(Required to replace Diaphragm).............P/N: FG-WG38-VLT
Spares
Diaphragm, silicone nomex-(Requires valve locking tool to fit)....P/N: FG-WG38-DIA
Manifold Gasket -Belpa Mica ...............................................P/N: FG-WG38-GSKT
Weld flange -(supplied with gasket and mounting bolts)...................P/N: FG-WG38-WFL
Spring 7 psi inner -White ......................................................P/N: FG-WG38-SP07IN
Spring 7 psi outer -Purple.....................................................P/N: FG-WG38-SP07
Spring 10 psi outer -Blue.......................................................P/N: FG-WG38-SP10
Steve Leerentveld from Redcliffe
Dyno & Performance is responsible for
this monster LJ Torana. This unique twin turbo
and supercharged setup uses two Pro-Gate 48s
and two Vee Ports to net a TOP 10 place at the
2004 Summernats and Street Machines “Street
Machine of the year” award .
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Wastegates
PRO-GATE 48
48mm Wastegate
P/N:
FG-WGATE-48
The professional’s choice for Horsepower!
Time proven reliability and extreme performance has made the Turbosmart
Pro-Gate 48 the external wastegate of choice by many of the world’s fastest drag
racers and builders of hardcore horsepower machines. The Pro-Gate 48s
design includes an investment cast stainless steel body, a one-piece billet valve
for strength and reliability and the unique temperature isolation zone to reduce
heat transfer to the diaphragm. The Pro-Gate 48 is supplied complete with a cast
stainless steel vee-band adapter kit for quick and easy installation. We have
successfully used Pro-Gate 48s on engines producing up to 1000HP.
• Race proven winner! Drag racers choice!
• Extensively developed body design and huge valve lift ensure unrivalled flow
• Silicone Nomex diaphragm - durability under extreme temperatures and stress
• Optimum actuator to valve ratio for precise boost control
• Supplied with vee-bands, weld flanges and springs to give 7, 10, 14, 17 and 21psi.
• Fully compatible with all Turbosmart Boost Controllers
Accessories
Garrett 42 (Australia only) to Pro-Gate adapter ............P/N: FG-WG48-AGRT
KKK 42 (Large) to Pro-Gate adapter ................................P/N: FG-WG48-AKKK
Racegate 42 to Pro-Gate adapter .....................................P/N: FG-WG48-ATRG
Exhaust coupling kit -Includes male and female weld flanges and a V-Band clamp. P/N: FG-WG48-ECK
Spring 3 psi outer -Brown ..................................................P/N: FG-WG48-SP03
Spring 5 psi outer -Pink ......................................................P/N: FG-WG48-SP05
Valve Locking Tool -Required to replace Diaphragm....................P/N: FG-WG48-VLT
Spares
Diaphragm, silicone nomex -Requires valve locking tool to fit. P/N: FG-WG48-DIA
Weld flange -Male ..............................................................P/N: FG-WG48-WFM
V-Band clamp ......................................................................P/N: FG-WG48-VBC
Spring 7 psi inner -Orange ................................................P/N: FG-WG48-SP07IN
Spring 7 psi outer -Green ..................................................P/N: FG-WG48-SP07
Spring 10 psi outer -Yellow ..............................................P/N: FG-WG48-SP10
Spring 14 psi outer -Red ....................................................P/N: FG-WG48-SP14
Smokin’ Joe Signorelli
consistently campaigned the Rotor Master 3/4 Chassis, 20B powered RX7 firing through two Pro-Gate 48s and a Supersonic for a
best of 7.584 @178.90 mph before concentrating on launching his new full chassis K&N backed RX7. The new car quickly ran into
the low 7’s powered by a Rotor Master triple turbo, triple Pro-Gate 48s, 20B engine package to run a PB of 7.336 @ 189.6 mph.
This places the car as the current runner up in the new ANDRA Sport Compact class of Pro RWD.
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Promotional Products
Check our website for
latest Promo Products
www.turbosmart.com.au
Vee Port key ring
P/N: PR-BOVKEY
Supersonic key ring
P/N:PR-BOVKEY-SS
Window Sticker 150mm, (6 inch)
P/N: PR-STIK-150
Window Sticker 300mm, (12 inch)
P/N: PR-STIK-300
Window Sticker 500mm, (20 inch)
P/N: PR-STIK-500
Window Sticker 900mm, (3 ft)
P/N: PR-STIK-900
Embroidered BLUE Baseball Cap
P/N: PR-BCAP-BE
Embroidered RED Baseball Cap
P/N: PR-BCAP-RD
Embroidered Turbosmart Knitted Beanie
P/N: PR-BEANIE
Printed Turbosmart T-Shirt
P/N: PR-TSHIRT -* * S, M, L, XL, XXL
Embroidered Turbosmart Pit Shirt
P/N: PR-PITSHIRT -* * S, M, L, XL, XXL
Embroidered Turbosmart Jacket
P/N: PR-JACKET-* * S, M, L, XL, XXL
Dalton Automotive’s
13B powered Pro RWD RX7
uses two Pro-Gate 48s,
a Megasonic BOV and
e-Boost for a PB
of 7.97 @165 mph with
more coming soon.
S&R Pro
Specialize in turbocharging motorbikes. Their 500+ Hp
Hayabusa GSX 1300R uses a huge turbo controlled by two
Vee Port BOV’s an Ultra-Gate 38 wastegate and an e-Boost
set to take advantage of running different boost pressures
in different gears. The Hayabusa has run a best so far of
8.76 @ 175 mph without wheelie bars!
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Research & Development
PAC Performance
Pac Performance is one of Australia’s leading performance workshops and builder of
one of the world’s fastest and most spectacular Sport Compact race cars. The Pac tuned
20B twin turbo system utilizes two Megasonic BOV’s and two Ultra-Gates with boost
pressure controlled by an e-Boost. This package has seen the full chassis MX6 storm
the quarter for a personal best of 7.08 @ 196.4 mph and is Australia’s current national
record holder for the ANDRA Sport Compact Pro RWD class.
The business is owned and run by two brothers, Rocky and George Rehayem who are at the forefront of the Rotary and
Import scene in Australia. Pac Performance has become a critical development and testing tool for Turbosmart products.
Turbosmart utilizes the Pac Performance fleet of race cars during track days and testing to prove our products in a way
that reassures us that we have reached a level of quality and development of the highest race car standards.
Rocky Rehayem on Turbosmart:
Q- Why is Turbosmart so successful?
“They are successful through products that work”
Q- Why do you use Turbosmart products?
“When you talk to Turbosmart you are talking to enthusiasts
that have technical and mechanical backing”
Ongoing Product Development
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Warranty
Show Time
SEMA Show 2003
Las Vegas, USA
Limited Lifetime Warranty
Turbosmart warrants their products to be free from defects in materials and workmanship for their usable lifetime.
Turbosmart will repair or replace such product or part thereof which, upon inspection by turbosmart, is found to be
defective in materials or workmanship. As a condition to the obligation of Turbosmart to repair or replace such
product, the product must be fitted in accordance with the Turbosmart fitting instructions .
WARNING! Incorrect use of Turbosmart products may result in damage to your vehicle. Failure to observe any notes or
recommendations may result in incorrect use of the products. Turbosmart products are intended for use in off-road racing
on
any damage caused to property or person, directly or indirectly related to the use of any Turbosmart product.
Active Automotive and Performance Centre is responsible
for this wild Commodore featuring a twin turbo 383 c.i. Holden V8
using two Pro-Gates and two Supersonic BOV’s. Eddy Tassone took
out the “Horsepower Hero” title at the 2003 Summernats and then
went on to lay down a huge 1525 hp at the wheels at a later dyno
comp. This mean feat was then backed up on the track when the
Commodore went an 8.11 @ 176.6 mph on only a 29.5 x 10.5 inch
slick.
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Turbosmart – Australia (Head Office)
www.turbosmart.com.au
sales@turbosmart.com.au
Local Phone: 1300 735 506
Local Fax: 1300 735 509
Time zone (GMT + 10 hrs)
Int Phone: +61 2 9798 2866
Int Fax: +61 2 9798 2826
North America: Johnston Research and
Performance Inc. - Distributor
www.turbosmart.com.au
USA Phone: (443) 557 0086
USA Fax: (410) 590 3892
Canada Phone: (905) 822 RACE (7223)
Canada Fax: (905) 822 3632
Europe: AET Engineering Ltd.
Distributor
www.turbosmart.com.au
Phone: +44 (0) 1924 894 171
Fax: +44 (0) 1924 890 394
New Zealand: Impact Autoparts
Distributor
www.turbosmart.co.nz
Phone: 0508 TURBOSMART (887 267)
Fax: 09 525 0449