SHOPTRK build
11-11-2012, 11:37 PM
#24
Thanks guys, it's coming together! Fired it up tonight, not intercooler piping or anything done, but the manifold, crossover, O2's and external gate are all done and in. Hoping to be doing burnouts by the weekend!
wld1985, I bought enough metal to make my manifold, crossover and downpipe/exhaust all for $435.49 shipped from AceStainless.com.
Here's what I ordered:
Manifold parts
4 -1.25" SCH10, 90* elbow 304L
1 - 1.25" SCH10 45* elbow 304L
1 - 2.5" SCH10 90* elbow 304L
1 - 2.5" SCH10 45* elbow 304L
2 - 1' SCH10 straight pipe 304L
I used a 3/8" thick, 1.75" primary header flange that I had laying around. The OD of the 1.25" SCH10 pipe is 1.660" so it fits the header flange with some decent room, made for easy welding. And the 2.5" SCH10 pipe had an OD of just about 2.8", it oval'd out nice for the turbo flange.
Crossover parts
2 - 2.5" 16ga 45* bend 304L
2 - 2.5" 16ga 90* bend 304L
5 - 2.5" (1' lengths) 16ga straight pipe 304L (I only ended up using about 2 feet of this...but you never know what you might need so I'd say order 3-4ft just to be safe in case you make an error)
My dropout came with stock manifolds, so I used that for the passenger side, and luckily it had the exhaust side flange with a stub still on it so I was able to weld right onto that. O2 bungs I had laying around as well. I bought a 2.5" Dynatech V-band assembly from Summit Racing for the turbo manifold/crossover joint.
Downpipe/exhaust parts
8 - 3" (1' lengths) 16ga straight pipe 304L
4 - 3" 16ga 90* elbow 304L
4 - 3" 16ga 45* elbow 304L
All that piping shipped, was $435.49 to my door, as stated before.
If anyone wants any info on what I've used or part numbers feel free to ask as I've got it all documented/printed/saved in a folder haha.
Making the turbo manifold was easier than the crossover to be completely honest. I've got about 3hrs give or take in the turbo manifold, and about 5hrs in the crossover and misc stuff like adding the O2 bungs and EWG flange. The crossover took a lot of tacking and breaking tacks and moving things around while trying to get everything to line up and fit the way I wanted it.
wld1985, I bought enough metal to make my manifold, crossover and downpipe/exhaust all for $435.49 shipped from AceStainless.com.
Here's what I ordered:
Manifold parts
4 -1.25" SCH10, 90* elbow 304L
1 - 1.25" SCH10 45* elbow 304L
1 - 2.5" SCH10 90* elbow 304L
1 - 2.5" SCH10 45* elbow 304L
2 - 1' SCH10 straight pipe 304L
I used a 3/8" thick, 1.75" primary header flange that I had laying around. The OD of the 1.25" SCH10 pipe is 1.660" so it fits the header flange with some decent room, made for easy welding. And the 2.5" SCH10 pipe had an OD of just about 2.8", it oval'd out nice for the turbo flange.
Crossover parts
2 - 2.5" 16ga 45* bend 304L
2 - 2.5" 16ga 90* bend 304L
5 - 2.5" (1' lengths) 16ga straight pipe 304L (I only ended up using about 2 feet of this...but you never know what you might need so I'd say order 3-4ft just to be safe in case you make an error)
My dropout came with stock manifolds, so I used that for the passenger side, and luckily it had the exhaust side flange with a stub still on it so I was able to weld right onto that. O2 bungs I had laying around as well. I bought a 2.5" Dynatech V-band assembly from Summit Racing for the turbo manifold/crossover joint.
Downpipe/exhaust parts
8 - 3" (1' lengths) 16ga straight pipe 304L
4 - 3" 16ga 90* elbow 304L
4 - 3" 16ga 45* elbow 304L
All that piping shipped, was $435.49 to my door, as stated before.
If anyone wants any info on what I've used or part numbers feel free to ask as I've got it all documented/printed/saved in a folder haha.
Making the turbo manifold was easier than the crossover to be completely honest. I've got about 3hrs give or take in the turbo manifold, and about 5hrs in the crossover and misc stuff like adding the O2 bungs and EWG flange. The crossover took a lot of tacking and breaking tacks and moving things around while trying to get everything to line up and fit the way I wanted it.
11-11-2012, 11:57 PM
#25
Not too many pics from today, I was hammering away getting things done haha.
Crossover pipe fitting
All welded up!
Since the 2.5" sch10 pipe is, obviously, round, and the Tial wastegate flange is flat, I didn't want to weld the tops and have to fill the entire edges of the EWG flange. After drilling a 1.75" hole in the manifold where I wanted the EWG, I rummaged around and found a 1.75" OD piece of 16ga steel. I cut it to about 3/8-1/2" (just stuck it in the chop saw and cut it haha), tapped it into the hole where it fit snug, tacked it into place, then pulled the manifold out and welded the EWG flange to that pipe. This picture is the first pass, I made a second over the sides to really fill it in and prevent that small section of pipe from potentially cracking over time.
Turbo manifold finished and ready for final install
That's all I've got for tonight. I'll get a lot more pics of everything installed and fitment stuff for y'all tomorrow!
Crossover pipe fitting
All welded up!
Since the 2.5" sch10 pipe is, obviously, round, and the Tial wastegate flange is flat, I didn't want to weld the tops and have to fill the entire edges of the EWG flange. After drilling a 1.75" hole in the manifold where I wanted the EWG, I rummaged around and found a 1.75" OD piece of 16ga steel. I cut it to about 3/8-1/2" (just stuck it in the chop saw and cut it haha), tapped it into the hole where it fit snug, tacked it into place, then pulled the manifold out and welded the EWG flange to that pipe. This picture is the first pass, I made a second over the sides to really fill it in and prevent that small section of pipe from potentially cracking over time.
Turbo manifold finished and ready for final install
That's all I've got for tonight. I'll get a lot more pics of everything installed and fitment stuff for y'all tomorrow!
11-12-2012, 09:34 PM
#27
Got around to installing some heater/coolant hoses today, the turbo oil drain, some intake stuff, just random odds and ends really.
Wastegate clearances
Ignore the giant coiled up turbo feed line haha...that was just to get by until I took the 5min to route the other 48" line properly and make it fit haha.
48" feed line installed
O2 sensor location, wastegate/etc.
Trimmed the passenger side harness a bit, removed the maf wires/plug and rerouted them over towards where the maf will be temporarily, going SD eventually.
Next I reclocked the compressor housing to give me room/clear the stock coolant reservoir and what not
I then moved on to getting the start of my intake/cold piping setup. With just the 4" 90* elbow I had the maf would hit on the alternator, soooo I dug around, found another black 4" straight coupler, I also happened to find a 4" piece of aluminum tubing about 2" long and some extra T-bolt clamps. Made a little adaptery type deal and she's done!
Coolant hose stuffs
Main reservoir/waterpump line has 3/8" or so clearance all the way around the EWG. I might ziptie it over to the lower rad hose to get it around 3/4-1" away, but we'll see.
Wastegate clearances
Ignore the giant coiled up turbo feed line haha...that was just to get by until I took the 5min to route the other 48" line properly and make it fit haha.
48" feed line installed
O2 sensor location, wastegate/etc.
Trimmed the passenger side harness a bit, removed the maf wires/plug and rerouted them over towards where the maf will be temporarily, going SD eventually.
Next I reclocked the compressor housing to give me room/clear the stock coolant reservoir and what not
I then moved on to getting the start of my intake/cold piping setup. With just the 4" 90* elbow I had the maf would hit on the alternator, soooo I dug around, found another black 4" straight coupler, I also happened to find a 4" piece of aluminum tubing about 2" long and some extra T-bolt clamps. Made a little adaptery type deal and she's done!
Coolant hose stuffs
Main reservoir/waterpump line has 3/8" or so clearance all the way around the EWG. I might ziptie it over to the lower rad hose to get it around 3/4-1" away, but we'll see.
11-12-2012, 09:35 PM
#28
On The Tree
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^ that,and what size/type is that turbo? Looks like a decent size.. I've got a few parts laying around for a project one day...I've got a nice black intercooler that should fit nicely behind the grill.. Very Detailed pics and write up, i like it..
11-12-2012, 09:38 PM
#30