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RSI: DIY Gen2 Twin Turbo Kit Install

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RSI: DIY Gen2 Twin Turbo Kit Install
Old February 3rd, 2013, 01:05 PM   #1
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RSI: DIY Gen2 Twin Turbo Kit Install

I’ve been going back and forth about making a build thread…I figured since I have yet to see a DIY install of the RSI Gen 2 turbo kit, I would do one. While I will not get into the specific details of all the components and specs, I will cover the basic install which is so easy a cave man could do it.

Before I start, I would like to give credit where it is due. Between Will, Paul, and Jeremy they have been class acts this whole time. I would never hesitate to do business with them again in the future. While the product might take a bit of time to receive, the quality and craftsmanship, labels and instructions have made this a no brainer DIY install. I would also like to thank Keith aka Hyph who I blame for all of this happening to me. As hard as I tried to stay away from modifying this car, Hyph gave me the nudge that pushed me off the cliff.

So to dive into the basics, here are some of the components of the kit I’m installing:
RSI Stage X Turbo Kit
RSI Stage 3 Fuel System
RSI Radiator
RSI Springs
T&D Rockers
3/8 pushrods
4in Side Exhaust

I have divided this install into 3 parts:
Cutting & Trimming
Turbo Kit Install
Fuel Kit Install

List of tools you’ll need:
An air compressor (at least 29 gallons)
Impact wrench
Air body saw
Hole saw arbor kit (3in & 1.75in)
3/8” npt tap & corresponding drill bit
I would say it has taken a little under 8 hours spent on my back, in the garage, to do all the cutting and to install the turbo kit components. Which in comparison to other projects I have had in the past, this has been a breeze and I wouldn’t hesitate to recommend this to someone who likes to turn wrenches and might not have advanced mechanical skills that most people associate to DIY projects.

Bumper support modified


Cutting holes for piping


Intercooler mounted up (keep in mind this is not the intercooler I will be using, this is just a temp until Tuesday)



Holes cut into frame, oil pump mounted, oil feed and return lines ran




Holes cut in side sills


Intake off for capping pvc and changing thermostat
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97 GTS - Full B&B header & exhaust, 1.7RR, K&N, Smooth tubes, SCT, Giggle juice, penske coilovers, CCW Wheels, Gen4 brake conversion, autoform diffuser, custom CF interior, etc...

Last edited by scorch; February 3rd, 2013 at 01:19 PM.
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Old February 3rd, 2013, 01:05 PM   #2
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170 t-stat


Upgraded springs


Coated headers


Header and springs installed


Midpipe installed



Charge piping installed



Upgraded 3/8 heavy duty pushrods



Coated intake manifold and valve covers

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Old February 3rd, 2013, 01:06 PM   #3
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more pics!

Twin Tial Q BOV are a true work of art and im happy RSI uses them as a standard component. (just a side note these flow almost 2x as much as the older 50mm tial)


this is a quick comparison between the old RSI base intercooler and the stage 3 (race) one offered. Please keep in mind RSI is releasing a new entry level intercooler so by the time this is posted it will be obsolete but i figured it would be nice to see the difference!
The new race intercooler is noticeably wider and is thicker (depth) which will affect just a little on how you trim the bumper support. nevertheless it was a quick 5 minute adjustment stepping up from the older entry level to race intercooler (figure this would be a good bit of info for any current owners looking to upgrade)


entry level thickness


race thickness


Let me restate why RSI is at the top of the market and why i believe this kit is currently the best on the market! not only is the price point perfect but the quality is second to none! The biggest thing is attention to detail and being able to install everything with basic tools without having to hack up the frame etc (keep in mind i dont mean to down anyone elses kit when i say hack up, but merely that for the average person that doesnt have the skill to cut and box up the frame to fit TT kit) Theres nothing that you have to sit there and figure out with this kit everything has been done for you and instructions with pictures do the job very well. for example below is a simple electrical connection i have had to do from scratch on some other projects i have done, while the actual task is relatively easy for me it still requires some electrical knowledge and research to build the a relay and make all the lines etc.. RSI takes care of that for you.


intercooler installed on the car



Bumper support on and everything fits like a glove (i would like to add the mount for the hood latch is awesome, while its really not a big deal its one less thing to think about)



stock radiator out awaiting arrival of the new RSI tripple pass (with the summer heat in the midwest i strongly recommend that if you're doing this tt install or any for that matter to address the engine cooling system)


more updates to come

Last edited by scorch; February 6th, 2013 at 12:52 AM.
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Old February 3rd, 2013, 01:06 PM   #4
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space for more pics
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Old February 3rd, 2013, 01:06 PM   #5
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and a little more space
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Old February 3rd, 2013, 01:32 PM   #6
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Looks great man thanks for putting in the work.
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Old February 3rd, 2013, 04:07 PM   #7
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Stage X turbo system. Going with twin 88's?


Dig the crinkle coat on the intake and valve covers.

Last edited by Disturbed 01; February 3rd, 2013 at 05:27 PM.
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Old February 3rd, 2013, 04:51 PM   #8
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Awesome writeup, I'll definitely be staying tuned in to this build
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Old February 4th, 2013, 09:20 AM   #9
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Looks great! Is there an upgrade to headers? Mine uses stock manifolds. Looking forward to seeing the results
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Old February 4th, 2013, 09:54 AM   #10
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Quote:
Originally Posted by utahviper View Post
Looks great! Is there an upgrade to headers? Mine uses stock manifolds. Looking forward to seeing the results
That is a stock manifold in the pic.
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Old February 4th, 2013, 10:18 AM   #11
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Great thread!
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Old February 4th, 2013, 12:37 PM   #12
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Thanks for the support guys more pics to come tommorow!
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Old February 4th, 2013, 12:47 PM   #13
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Looks great man, cannot wait for mine to get done as well... like the look of those coated headers with the coated manifold and covers.
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Old February 6th, 2013, 12:52 AM   #14
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updates in post 2
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Old February 23rd, 2013, 12:03 PM   #15
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it wont let me edit previous post so I'll just add it to this post. car is completed but i just havent had a lot of time to go through all the pics and post up. i will update with more pics and vids next week hopefully. thanks for looking

Precision 46mm Wastegates




T&D Rockers



Driver’s side wastegate on



Passenger side wastegate on


Ground clearance with dumps and pump etc…


T&D Rockers installed

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Old February 23rd, 2013, 12:04 PM   #16
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Fuel System laid out


Fuel rails and intake pipes test fitted.



Howe radiator new vs old. Keep in mind no hardware comes with radiator so u will need new bolts for fan attachment, and fittings for drain and overflow.




RSI triple pump setup! Freaking work of art! Best fuel system on the market hands down!


All went in with ease!


Ran lines.. keep in mind it makes it a ton easier to half way loosen the fender tub area.


Lines runs down the trans tunnel.

Pump wiring all done. It was literally drop in nothing to think about.
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Old February 23rd, 2013, 12:04 PM   #17
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Manifold and rail in test fit along with charge piping



Fuel system complete took a total of 2.5hrs to install. I did add a fuel pressure guage to the fuel rail to make it easier when working on engine and or debugging issues .


Fuel Pressure regulator mounted




Boost controller mounted and equal length lines ran and T’d for both pressure side and top wastegate side
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Old February 23rd, 2013, 12:48 PM   #18
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Looking good keep up the good work man!
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Old February 23rd, 2013, 05:10 PM   #19
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Not sure if it's an issue for you, and it's hard to tell the exact spacing in that pic, but I think NHRA rules require the FPR to be at least 6" off the firewall. Just FYI in case you plan on hitting the track. Some folks ignore it and just mount straight to the firewall for ease of installation and cleanliness of plumbing.
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Old February 23rd, 2013, 05:19 PM   #20
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Looks good. Get some miles on it them strap it to a dyno, wonder what it will do.
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