My somewhat DIY turbo setup NEW CAR/CAGE PICS 1/8/09

[turbogt]

First off this site is great. I like reading about all the buildups that you guys do in here and I have started my own turbo project. I picked up a turbo kit from a guy who made it himself and everything looks in real good condition. Garret T-67 .96 AR exhaust. Uses shorty headers turned around and 2 1/2" crossover and a 3" downpipe. I picked up a new IC from E-bay for a decent price. I also have a DFI gen6, 42lb injectors, 255lph in-tanl pump, MSD6AL. I'm shooting for about 400hp out of the stock engine. I have never done any real fabricating or welding on my own but I'm making new piping from the turbo to the IC and the IC to the throttle body. I have a 220v mig welder and I'm picking up some argon next week so I can start making some piping.

Here are some pics of the IC that I just mounted. I had to do a ton of cutting to the front bumper brackets and the bumper itself. I also ditched the foglight brackets for now. As you can see the top outlet is heading right into one of the bumper supports. I'm hoping that I can get a 3" -> 2 1/2" reducer at a 45degree angle and clear the support. I might have to trim a couple of inches of the IC to get the piping in. Any ideas?

I also attached a mock up pic of the turbo setup. The compressor housing is not clocked right BTW. I also have the drivers side header wrapped. That stuff is a real pain to get on when it starts to come apart. I plan on using the high temp spray to seal up any loose fibers.

Ben

[turbogt]

pic below

[turbogt]

mock up

[turbogt]

better pic of the intercooler inlet and outlet

[botietr]

Looks nice..im going through the same thing right now,,Good Luck

[tkelly27]

looks good!

[superwillard]

the intercooler looks nice who makes is and if you don't mind how much was it.

[turbogt]

I picked it up off of this guy and I paid $298 plus shipping. This link is to a 3" core but mine is a 4"

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=7978878969&category=33742

Thanks for the comments!

[Kellyo77]

Could you not move the cooler up a bit so the pipes go over and under the bumper support? Just wondering. Looks good!

[mooktank]

It doesn't look like that intercooler is even going to work. The two inlets on one side and none on the other. Looks like air will just go through without getting the fins.

[turbogt]

I couldn't move it any higher as the front bumper was completely in the way. Plus with a 3" inlet and outlet there was no way to make the piping work with the bumper support.

This being my first project an all making pipes and brackets and such, I didn't want to spend big money on a intercooler. Most intercoolers with 1 in and 1 out on the same side were starting around $450. My turbo is on the passenger side and I didn't want to run tubing across the car and into the intercooler on the drivers side. So even though it isn't a vertical flow I think it will cool the air. I plan to hook up my fluke meter once everything is runnin and see what the in/out temps are as I too am curious Plus if anything we can learn how important it is to get a vertical flow! I'm always the guinea pig in everything i do

I would work on the car today but it's getting warm and i'm off to the lake to do some wakeboarding :rockon:

[BOSs5.0]

Originally posted by mooktank
It doesn't look like that intercooler is even going to work. The two inlets on one side and none on the other. Looks like air will just go through without getting the fins.

Do you see the devider welded in the middle...?

[turbostang]

Originally posted by turbogt
I couldn't move it any higher as the front bumper was completely in the way. Plus with a 3" inlet and outlet there was no way to make the piping work with the bumper support.

This being my first project an all making pipes and brackets and such, I didn't want to spend big money on a intercooler. Most intercoolers with 1 in and 1 out on the same side were starting around $450. My turbo is on the passenger side and I didn't want to run tubing across the car and into the intercooler on the drivers side. So even though it isn't a vertical flow I think it will cool the air. I plan to hook up my fluke meter once everything is runnin and see what the in/out temps are as I too am curious Plus if anything we can learn how important it is to get a vertical flow! I'm always the guinea pig in everything i do

I would work on the car today but it's getting warm and i'm off to the lake to do some wakeboarding :rockon:

 It's hard to tell from the pictures but it looks like you could use molded silicone elbows out of the tank and make it work just like it sits -OR- you could use tight radius J bends to make the turn out of the intercooler. Again it's hard to tell from the pics but it may be worth a shot. What about welding a 3" weld el to the top of the tank to make the turn?? just some ideas..

edit: after looking at the pic again - it looks like the silicone elbow would work on the top and the bottom outlet could be straight :confused:

[turbogt]

Bos you are the man, looks like i need to read a little closer next time

Turbostang i was thinking right along those lines. I'm going to order 3" to 2.5" 45 degree angle reducer and hopefully clear the bumper support. If worst came to worst i could always cut another inch off the upper IC outlet to give me a little more room. We'll have to see!

[turbogt]

Quick update: I bought a new ATI balancer because of the high miles on the motor. I didn't want the stock POS to go away on a trip down the track. I punched and tapped the oil drain for the turbo. Had the WBO2 sensor bung welded in on the downpipe. I also wrapped all the hotside and sprayed on the DEI 1500deg spray to hold all the wrap together.

[turbogt]

Can anybody say degrease :bling: There is something about a new harmonic balancer  
:rockon: pic below

[turbogt]

nm

[Legendary]

Originally posted by BOS"s5.0
Do you see the devider welded in the middle...?

That's what I was thinking.  THe divider would stop the air from traveling up that first end tank right?

[turbogt]

yes, that's how it works. Air flows in on the bottom port, goes across the bottom, makes a 180degree turn, then out the top.

[turbogt]

Well I've made some major progress lately. I picked up a dfi gen6 off another board member and I've been very anxious to see if it would actually worked. I finally got the car to a point where i could test out the computer and it fired my car right up. So i've just started the intercooler piping and I've got this done so far. Now once i finish the piping and about a thousand other misc. things I can finally get the car on the street! Some major projects that are left are plumb the water/alcohol injection, make a 3" exhaust, and finish the wiring of the new dfi, gauges, and electric fan.

[turbogt]

The turbo clocked right

[mystang]

toast your alternator yet?  yo might want to put a heat shield around that thing.  Besides that looks good

[turbogt]

oh yeah I still have to do that also

[turbogt]

Well finally had a chance to do some more work on the car and I feel I'm about 90% done. I have a bunch of pics to post so here they are. Also how do you put up multiple pics in the same post without making a new post for every new picture?

thanks, Ben

[turbogt]

Here is the inlet and outlet piping installed with the inner bumper support trimmed and installed.