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HybridZ

Feeding My Addiction (turbo build)


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  • 3 weeks later...

I was going to go that route but it was going to require changing the coil-pack location. I'm trying to get this done with the least amount of modifications to what I already have. So far it's going as planned. Until I get to the down pipe that is.

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I've been working here and there on the car the last couple of weeks. Kansas weather bites! One day it will be sunny and 70* outside and the next its 30* and snowing.

Anyways, enough whinning and on to the good stuff. I needed the turbo to set a little closer to the engine so I made a different turbo mount that is probably 5 time more solid. I'm almost done with the crossover as well. Just need to finish up the wastgate merge and tig it onto the crossover. The welds don't look the best but in my defense it's my first time welding stainless tubing. lol. The welds look nicer on the inside then they do on the outside because of the purge welding.

New turbo mount

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Purge tig welded crossover.

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Wastegate merge

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  • 2 weeks later...

More pictures!

 

Cut some holes with a plasma cutter in this pic. A fellow gear head sliced them out in no time for me. I realy need to get a plasma cutter.

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Burned in wastegate merge.

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Installed crossover with wastegate.

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Got started on the down, up, and over pipe. That exhaust is going to be so dizzy it's going to puke when it finaly gets out.

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WG merge looks good.  Will you be using the O2 sensor pictured for a wideband port?  You might do some looking around on that. In my research I found that you want your wideband within 18" of the turbo outlet. My system doesn't use O2's at all, only a wideband.

 

Looking good though!

 

Also, I'd HIGHLY recommend changing that fitting on the inlet of your fuel rail. They have ones now that actually thread in from the back side, along with slipping over the factory push on fitting for a positive lock.  I had mine come off last year on a WOT pull, and doused the headers (and EVERYTHING in the engine bay) with gas. I'm very lucky it didn't start a fire, or I'd have been sitting on the side of the road watching the car burn.  

 

Tip #2 - Carry a fire extinguisher. It would be terrible for anyone to watch their car burn down on a country road or even return road at the track for that matter!!!!

Edited by SUNNY Z
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I just got my replacement fuel push on connectors yesterday. I had the black ones with the plastic clip then read on a few different forums of people here and there having them pop off and catch or almost catch the car on fire. I decided to replace them with the blue screw together ones while I'm doing the plumbing just to be safe.

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WG merge looks good.  Will you be using the O2 sensor pictured for a wideband port?  You might do some looking around on that. In my research I found that you want your wideband within 18" of the turbo outlet. My system doesn't use O2's at all, only a wideband.

 

Looking good though!

 

Thanks Sunny Z. The O2 bung that is pictured is just bank 1 for the ECM. Bank 2 is bung is on the other end of the crossover just after the 90. The wideband is going in the downpipe.

 

Also, I'd HIGHLY recommend changing that fitting on the inlet of your fuel rail. They have ones now that actually thread in from the back side, along with slipping over the factory push on fitting for a positive lock.  I had mine come off last year on a WOT pull, and doused the headers (and EVERYTHING in the engine bay) with gas. I'm very lucky it didn't start a fire, or I'd have been sitting on the side of the road watching the car burn.  

 

Tip #2 - Carry a fire extinguisher. It would be terrible for anyone to watch their car burn down on a country road or even return road at the track for that matter!!!!

I remember your post on your build about the fitting coming off during a pull. Man that would have been terrible to catch on fire. I'm glad it didn't.  I was also sceptical about the fitting holding so I had already decided to use safety wire to hold it from popping off. I've also got safety wire holding the fittings on the corvette filter/regulator.  In this pic I had just cut it off to remove the fitting and intake. I will check out the fitting your talking about. I didn't even know it was an option.

By the way, the fire extinguisher has a nice cozy home behind the passengers seat. :)

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I wonder if some peoples came off because they weren't put on all the way. One of mine snapped right on, the other I thought I had on, but never felt the click on. I had to pull pretty hard for it to come off but it did. In order for me to get that one to click, I literally had to lean on it will all 220 of my pounds against a bench, then I finally felt the click. I tried briefly to get that one off a few days ago and it won't budge now. I hope I can get it off to put my new ones on.

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  • 3 weeks later...

We have been having some nice days here all in a row lately so I've been able to get more done.  It's acctually starting to come together and look like a turbo car now.  It's so exciting!

 

I've also decided to change my fuel. I was going to go with E85 but with limited availability in my area and the difference in consumption, I have decided to go with good old 91 octane with water/meth injection. I have an aluminum fuel line also and E85 likes to eat aluminum. :(

 

More progress pics.

 

Mostly finished down pipe.

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I made a flange to help support the metal where I cut out a 4 inch hole.

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Passenger side fender exit exhaust. I'll be purchasing or making a flange for this opening also

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Mounted the intercooler with just enough room for the fan. Also cut off straight tubes from intercooler and welded on elbows.

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Most of the charge side is done. I just need to figure out a air intake setup.

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Custom bead roller. (Harbor Freight wire cutter/crimper)

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