Joff and MrsJoff's Chaste White BorgWarner FD build

joff · 01-11-2011, 10:57 PM

I got all my intake tubing cut and welded this weekend. I was able to keep all bends relatively gentle, but man I am really getting sick of having to use this hack saw. Cutting a 4" cast aluminum elbow in half by hand (and all the other pieces) was a major PITA.

I was able to get the fitment between sections within about 1/8" which should make couplers blowing off almost impossible. To minimize number of couplers, I also cut off the end of the cast Rotary-Works elbow and had pipe welded to that. I'm tempted to use Wiggins clamps on the intercooler piping, but don't really dig the purple anodizing.

Next I'm going to grind the welds down, find somebody to put a bead on the ends and get the pieces powder coated wrinkle-black. BOV mount is going on the intercooler hot side.

Tried to position the air filter perfectly for a cold air/ram air intake. This pic is from the front looking into the V of the V-mount with the bumper off.

I do like the more gentle angle of the Rotary-works TB elbow as compared to the >90degree Greddy ones, but I don't think I'll be able to reuse the stock strut bar now without some custom mounts-- it sits pretty high. RCCAZ and dregg100 gave me a heads up Saturday that cutting off the air pump mount on the water pump housing would clean up some of the fuel rail plumbing later so I cut that piece off too with the hacksaw.

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01-11-2011, 10:57 PM	#11
joff Rotary Fanatic Join Date: Dec 2008 Location: Mesa, Arizona Posts: 114 Rep Power: 17	I got all my intake tubing cut and welded this weekend. I was able to keep all bends relatively gentle, but man I am really getting sick of having to use this hack saw. Cutting a 4" cast aluminum elbow in half by hand (and all the other pieces) was a major PITA. I was able to get the fitment between sections within about 1/8" which should make couplers blowing off almost impossible. To minimize number of couplers, I also cut off the end of the cast Rotary-Works elbow and had pipe welded to that. I'm tempted to use Wiggins clamps on the intercooler piping, but don't really dig the purple anodizing. Next I'm going to grind the welds down, find somebody to put a bead on the ends and get the pieces powder coated wrinkle-black. BOV mount is going on the intercooler hot side. Tried to position the air filter perfectly for a cold air/ram air intake. This pic is from the front looking into the V of the V-mount with the bumper off. I do like the more gentle angle of the Rotary-works TB elbow as compared to the >90degree Greddy ones, but I don't think I'll be able to reuse the stock strut bar now without some custom mounts-- it sits pretty high. RCCAZ and dregg100 gave me a heads up Saturday that cutting off the air pump mount on the water pump housing would clean up some of the fuel rail plumbing later so I cut that piece off too with the hacksaw.