Just about done with the new intake plenum!

Took the throttle body flange I cut out and drilled the center hole for the air to pass through:
http://i254.photobucket.com/albums/h...C/IMG_0705.jpg
http://i254.photobucket.com/albums/h...C/IMG_0739.jpg
http://i254.photobucket.com/albums/h...C/IMG_0740.jpg
http://i254.photobucket.com/albums/h...C/IMG_0741.jpg

Took a while to cut but made it through.
http://i254.photobucket.com/albums/h...C/IMG_0742.jpg

Perfect port match, no filing needed:
http://i254.photobucket.com/albums/h...C/IMG_0743.jpg
http://i254.photobucket.com/albums/h...C/IMG_0744.jpg

Drilled and tapped the mounting holes:
http://i254.photobucket.com/albums/h...C/IMG_0745.jpg

Welded the flange to the plenum:
http://i254.photobucket.com/albums/h...C/IMG_0746.jpg
http://i254.photobucket.com/albums/h...C/IMG_0747.jpg
http://i254.photobucket.com/albums/h...C/IMG_0748.jpg

Bolted up:
http://i254.photobucket.com/albums/h...C/IMG_0749.jpg
http://i254.photobucket.com/albums/h...C/IMG_0750.jpg
http://i254.photobucket.com/albums/h...C/IMG_0751.jpg

Inside:
http://i254.photobucket.com/albums/h...C/IMG_0752.jpg

Mounted:
http://i254.photobucket.com/albums/h...C/IMG_0760.jpg
http://i254.photobucket.com/albums/h...C/IMG_0761.jpg
http://i254.photobucket.com/albums/h...C/IMG_0762.jpg
http://i254.photobucket.com/albums/h...C/IMG_0763.jpg
http://i254.photobucket.com/albums/h...C/IMG_0764.jpg

Notice the easy access to the oil filter and all of the clearance I have.

Now all that's really left on this piece is to weld on a few bungs for temp sensors and pressure sensors, and also a throttle cable bracket. But I need to figure out where I'm putting all the accessories first (wastegate solenoid, map sensor, fuel pressure regulator, etc... I'm trying to keep it all pretty consolidated)

Also finding myself having to redo a few things. The radiator and thermostat housing bungs just don't line up well enough with the fittings on. So I'm relocating them. Since I'm making my own AST, I don't really need the capacity of the thermostat housing, so I chopped it off, and now I'll weld a flat cover on it and then add a -16AN bung coming straight out of it. This will go to the top of the radiator.

Chopped up this piece that I've spent a lot of time on, but that happens I guess.
http://i254.photobucket.com/albums/h...C/IMG_0755.jpg
http://i254.photobucket.com/albums/h...C/IMG_0754.jpg
http://i254.photobucket.com/albums/h...C/IMG_0756.jpg

I'll clean up the top of the water pump housing too, and add the -16 bung to it, and also delete all the old nipples that are pressed into it. And a -10 bung for the heater core hose.


I also had to give myself more room for the piping to bend gradually coming out of the FMIC, so I had to go straighten out the brackets to make it completely vertical. This will make ducting a lot easier, and smoother bends for the piping.
http://i254.photobucket.com/albums/h...C/IMG_0758.jpg
http://i254.photobucket.com/albums/h...C/IMG_0757.jpg

More updates coming soon!

Damn dude.... you got a lot done after I took my sick ass home to go to sleep :rofl:

For the T-stat cover.... I should have a length of the pipe left over that I used... Ordered a foot, and used 2" I think....

Treated myself to a day off of work to work on the car yesterday. Got quite a bit done!

Finished up the thermostat housing and waterpump housing, cleaned it up quite a bit.

Cut a piece out of the left over 1/2" plate that I used for the throttle body flange, drilled the mounting holes and then drilled a hole in the center for the hole saw:
http://i254.photobucket.com/albums/h...C/IMG_0772.jpg
http://i254.photobucket.com/albums/h...C/IMG_0773.jpg

Hole saw action:
http://i254.photobucket.com/albums/h...C/IMG_0774.jpg
http://i254.photobucket.com/albums/h...C/IMG_0775.jpg
http://i254.photobucket.com/albums/h...C/IMG_0776.jpg
http://i254.photobucket.com/albums/h...C/IMG_0777.jpg
http://i254.photobucket.com/albums/h...C/IMG_0778.jpg

And a -16 AN bung
http://i254.photobucket.com/albums/h...C/IMG_0780.jpg

Cut and ground down a lot of the water pump housing. Now I've got a -16AN for the lower radiator hose, -10AN for the heater core hose, and a -4AN on top for the new AST. I also added a 1/8npt bung to relocate the sensor for my gauge.
http://i254.photobucket.com/albums/h...C/IMG_0781.jpg
http://i254.photobucket.com/albums/h...C/IMG_0782.jpg
http://i254.photobucket.com/albums/h...C/IMG_0783.jpg
http://i254.photobucket.com/albums/h...C/IMG_0784.jpg

Installed:
http://i254.photobucket.com/albums/h...C/IMG_0789.jpg
http://i254.photobucket.com/albums/h...C/IMG_0788.jpg

Everything still clears:
http://i254.photobucket.com/albums/h...C/IMG_0787.jpg

Here's my custom AST, made out of a $20 catch can from ebay, a few bungs, and a billet pressure cap holder.

What it started as:
http://i254.photobucket.com/albums/h...OCT-C-SL-1.gif

What it is now:
http://i254.photobucket.com/albums/h...C/IMG_0785.jpg
http://i254.photobucket.com/albums/h...C/IMG_0786.jpg

what made you decide to keep the AST?

Also have the intercooler in its final location. Soon to be tied down with M8 x 1.25 RivNuts and socket cap bolts.
http://i254.photobucket.com/albums/h...C/IMG_0802.jpg
http://i254.photobucket.com/albums/h...C/IMG_0801.jpg

This layout is going to look amazing:
http://i254.photobucket.com/albums/h...C/IMG_0790.jpg
http://i254.photobucket.com/albums/h...C/IMG_0791.jpg
http://i254.photobucket.com/albums/h...C/IMG_0793.jpg

Shortening the bends that couple to the intercooler:
http://i254.photobucket.com/albums/h...C/IMG_0794.jpg
http://i254.photobucket.com/albums/h...C/IMG_0795.jpg
http://i254.photobucket.com/albums/h...C/IMG_0796.jpg

You can see them poking up here:
http://i254.photobucket.com/albums/h...C/IMG_0797.jpg
http://i254.photobucket.com/albums/h...C/IMG_0798.jpg

The supercharger outlet/FMIC inlet pipe will run right next to this one:
http://i254.photobucket.com/albums/h...C/IMG_0799.jpg

Had to trim the mount on the supercharger to clear the intake pipe:
http://i254.photobucket.com/albums/h...C/IMG_0803.jpg
http://i254.photobucket.com/albums/h...C/IMG_0805.jpg

Pretty close to what it will look like:
http://i254.photobucket.com/albums/h...C/IMG_0800.jpg
http://i254.photobucket.com/albums/h...C/IMG_0804.jpg
http://i254.photobucket.com/albums/h...C/IMG_0804.jpg

DIBS on first ride at DGRR!!!

Damn, this thing is gonna be nasty. I love the fabrication alone. I really hope to be this skillful someday. Well done!

Yeah, me too haha, Brian sure can weld. I feel like I'm getting pretty decent at designing, cutting, and prepping everything, but the welding is what really brings it all together. Plus, two heads are better than one, it's always good to have input on the design of all these pieces. It's truly a tag team effort haha.

thats for sure, hes always been my go to guy for all my welding/fabing/idea needs lol i wished that he was ready to jig up manifolds at the time i had mine done, not that theres anything wrong with mine, im just the faithful return customer kind of guy

wire relocation has started:
http://i254.photobucket.com/albums/h...g/IMG_0813.jpg

Anyone have any idea why my new harness' relay box is different than my current 94 R2?

94 R2 in my car:
http://i254.photobucket.com/albums/h...g/IMG_0824.jpg

My new harness being modified, with the cover from the 94 R2 relay box seen above. Take a look at the difference between the Air Pump relay sections. Mine has one big relay, the new one has a place for 2 small relays.
http://i254.photobucket.com/albums/h...g/IMG_0825.jpg

Awesome build!

Makes me wish I had a garage and a TIG :(