Join Date: Mar 2005
Location: Scottsdale, Arizona
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Turboing is not a easy or cheap process. If you dont have alot of disposible income and/or a main daily driver dont even THINK about turboing your motor.
Your first custom turbo setup will always blow the motor, I dont care what PSI you run. You'll almost certainly detonate unless someone who knows what they are doing programs it for you and you use a setup that is already proven to work.
There is no such thing as a "safe" PSI when dealing with custom setups because every setup will produce different CFM @ x PSI..CFM is what matters.
The motor you have there is turbo-able, but if you use a thicker HG make sure to at least go with a MLS HG.. and don't go too thick. Dont use copper unless you plan on o-ringing the block/head.
I've done a custom turbo on my e30 and I do them for a living where I work and turboing is 3 things: not easy, not cheap, not for your main vehicle.
If you go ahead with it, I HIGHLY HIGHLY HIGHLY recommend you pick up Corky Bell's book "Maximum Boost"...some things are in-accurate but overall its considered the bible for many when it comes to understanding turbos.
Btw: depending on the setup and how much custom welding you can do for yourself, plan to spend at least $4,000 USD making a semi-decent custom turbo from nothing. All the piping, small fittings you dont think about, ignition and fuel control, injectors, turbo, etc.. all add up, fast.
That $$ ammount is assuming you dont touch the internals of the motor and dont upgrade to lower C/R pistons, etc..
people will say you can build one cheaper, but they usually dont add every penny spend on small fittings, etc. trust me, I have. And I bought most my parts on ebay or @ a junk yard for my e30 turbo setup.