I wasnt happy with the manifold. The turbo sat a little farther forward than I wanted and was twisted in relation to the engine. It was making lining up the intake pipes and cutting a downpipe difficult. So last night I cut one of the welds and repositioned it then welded everything up. Spent time leak testing the manifold and welding a couple pinholes. Manifold is totally finished now and my turbo is positioned perfect!

Unfortunately after I finished it and was cleaning up the garage I heard a gas leak in my welder. Found the gas line that goes up through my wire to the gun had a leak. Lost a third of my tank of gas to it too Now I'm off to home depot to track down some tubing to fix it.

Hoping to get my Downpipe done tonight then button things up tomorrow.

 

Unfortunately noone carries 3/16" nylon tubing I need to fix my welder around here. Smallest I could find was 1/4". I ordered some online, but no way am I going to wait for it. I patched up the leaking line by slipping some 1/8" tubing over the spilt with some goop in to seal it up. It may be leaking a little, but my tank pressure is holding and I can weld!

So I got my downpipe cut and tacked together. Its a bitch to get wrestled down into the engine bay. I actually have to have the motor mount hanging loose to get it through. That top motor mount bolt is gonna be a pain to get on but should be doable. Now I gotta get my wastegate tube made and welded on the downpipe along with the two 02 sensor bungs.

 

So if you are posting at 7:56 in the am today, does that mean you are going to have it back together to make it to Saturday's meet?

 

I'm trying!

 

My welder failed again and screwed up my day. This time i couldnt patch it. It will have to wait till my new line comes in. Fortunately I have a friend with access to a good welder and ran over there to finish my downpipe and weld together a downturn with a flange I can clamp it to my downpipe and run the car sans exhaust I'll weld up my exhaust system once my gas line comes in for the welder.

Now I just need to get my Downpipe wrapped and installed. Mount my intercooler. Then cut my intercooler/intake pipes and get everything hooked up.

Almost there.....

 

Are you done yet?

:D

 

lol Had to spend the day with the family. Just woke up from a nap to go out and try to button it up

 

I have gotten nowhere. Turns out the way the turbo is clocked on my manifold that the oil drain fitting wont fit on it. The actual hot side housing inlet flange blocks the huge *** AN fittings that need to go on it. I've taken those fittings aprt and put them back together so many times they are probably going to leak....

 

Progress:

 

More progress:

 

wow everything is coming along very nicely. good job!

 

Thanks


Later Today:
-Need to run out and buy a few hose clamps to button up the coolant lines.
-Then cut a few intercooler pipes and get that all together.
-hook up my wideband and tru-boost to a power source.
-add fluids
-flash to my base tune
-Start the car!

 

looking sweet .
That maf location will cause a few probs though

 

Still have to open up the hole into the bumper a bit so I can straighten out those pipes better.
Also going to have the MAF a bit farther forward and add some striaght pipe behind it as well.
I bought 3' of that 3.5" tubing so I can play around with it.

 

The build looks awesome! Having said that, that BOV looks awful tall to be standing up right there, is that the final mounting angle/position for it?

 

the maf location seems fine to me, but you going to run into a problem if you don't recirculate the the bov back between the turbo inlet and the maf.

if you don't the bov will actually suck in air at idle or crusing speeds, this will be un-metered air and the car will run really rough. as its getting more air then it thinks

if you recirculate the bov between the maf and turbo, then you will be fine because it will suck in metered air.

I hope this makes sense

 

Yes; it will be problematic if you don't recirculate - but you can tune it to stay closed at idle and part throttle - you may just get stalling. When BOV's open as a rule they let air out; and the car runs rich.

The only BOV that reliably opens in all engine vacuum is the Syncronic; and it was designed to do so.

 

Nah in that pic the BOV pipe is sitting on top of another one. It will sit far lower once its actually connected

Going to try to run without recirc. As sensitive as the Maf is to any turbulence and as little room as I have to get straight smooth pipe in there I'm afraid I wont be able to do so without screwing up the Maf readings .

My intent is to eventually get the synchronic BOV to match my wastegate.

 

got to be carefull with those couplers that attach to the inlet of the turbo. They will collapse and suck closed when hot enough.

 

hks > synchronic

 

Don't make me hurt you wee man....

 

Kane gets a bit nasty with a "sodering iron" if provoked LOL

 

 

Ran into some issues, will try to start it tonight after work.
I"m going to have to completely redo my intercooler pipes though. Intercooler sits too far forward and the bumper wont fit back on.

 

I love watching this build and commend u on the ***** to DIY. I would love to do something similar, but I just don't have the funds. Would really like that t70 turbo kit out there but where do I get 6 grand from.... Where do you guys find the extra money to do all this stuff? My car payment/ins is $500/mo. Rent and bills $800/mo. I bring home about $2200/mo but for some reason everything is so damn expensive. Food, gas, beer beer beer.... And the wife. Guess I'm jealous LOL.