FD budget..ish track day build

DieselDakota · 03-30-2015, 01:07 PM

Alright on to the more recent stuff, so far is up to the end of the 2014 season and onto my current project.

Turbo

I tore out the DP, the stock twins, etc and did a test fit with my friends manifold made by turblown.

Here is my friends manifold on the engine without the turbo. it keeps everything super low.

Blocked off the rear turbo oil drain.

Since I don't have my manifold materials here, might as well start getting ready to copy.

My early reading week project was to fab up a welding cart and get my welder off the work bench. I didn't take any pictures building it but here is the final result.

This runner is a pain in the ass.

Started practicing little tacks since I hadn't done it before.

Started tacking the first runner together, its shortly after this that things started going wrong on this side. After tacking the pipes enough, I started heating and trying to bend the pipe to match the T4 flange and its a bitch, it also has the nice side affect of ruining all the fitting I had already done but that was to be expected.

I fucked up this runner as well and took to much material away. guess I get to start that over again. on the bright side I managed to get my little 90 to match up with the turbo flange somewhat.

here you can see the gap on the back where I took away to much material

Its also going to take a long time to get the two pipes to come together nicely as they now interfere.

DieselDakota · 03-30-2015, 01:09 PM

I went back out after supper. I managed to close up the gap pretty good on the one runner by fooling around a bit, still a bit of a gap but not nearly as bad. I didn't manage to stretch the other runner much better so I fooled around and centered it.
From the start I knew I would be laying a ton of weld between the pipe and both flanges, this will be because I will grind the flow path smooth and I will have to build up at least past were I intend to grind, this is why I didn't care a lot about the flange fitments, I would have liked them better but I was getting tired of just wasting time.

So once I was happy with all the fitment I tacked everything together so that I could do a test fit tomorrow with the turbo on the car.

here is some pics. I really should have wire wheeled it before tacking it up, it looks so bad now. I'll have to make sure not to forget that when it comes apart for the final welding. I'm pretty confident it will fit just fine, now I'm trying to find some welding friends who will help me with the important bit for some beer etc.

looks good after some machining. not pretty but it will be strong and work good. the turbo is going into a pretty tight space and it was hard to test fit, I was fairly confident it wouldn't fit after machining. I was however happily surprised. it fits and now its onto fabricatinging the exhaust.

DieselDakota · 03-30-2015, 01:15 PM

Alright this brings me up to modern day. I should win some kind of award for the smallest scroll bar ever in a build thread.

1. Currently I need to build a bracket to hold the wastegate canister as the one that came with the turbo won't work because of how the turbo is clocked.
2. I still need to make up oil lines and coolant lines to the Turbo.
3. I need to buy a wideband, currently looking to find a good canadian source for the innovate motorsports 2 in 1 boost and wideband kit.
4. I need to fab ub the downpipe and midpipe as well as modify my catback, this is waiting on the 3"GT vband flange for the turbo that I mistakenly thought was the same as any 3" vband flange.
5. I'm trying to piece together a fuel system, I have a friends system with some old EV1 1680 secondaries and the stock 550 primaries. this will be my backup plan depending on what else I can piece together. I'm also still trying to find a cheap used datalogit.

03-30-2015, 01:07 PM	#1
DieselDakota The Newbie Join Date: Nov 2012 Posts: 29 Rep Power: 0	Alright on to the more recent stuff, so far is up to the end of the 2014 season and onto my current project. Turbo I tore out the DP, the stock twins, etc and did a test fit with my friends manifold made by turblown. Here is my friends manifold on the engine without the turbo. it keeps everything super low. Blocked off the rear turbo oil drain. Since I don't have my manifold materials here, might as well start getting ready to copy. My early reading week project was to fab up a welding cart and get my welder off the work bench. I didn't take any pictures building it but here is the final result. This runner is a pain in the ass. Started practicing little tacks since I hadn't done it before. Started tacking the first runner together, its shortly after this that things started going wrong on this side. After tacking the pipes enough, I started heating and trying to bend the pipe to match the T4 flange and its a bitch, it also has the nice side affect of ruining all the fitting I had already done but that was to be expected. I fucked up this runner as well and took to much material away. guess I get to start that over again. on the bright side I managed to get my little 90 to match up with the turbo flange somewhat. here you can see the gap on the back where I took away to much material Its also going to take a long time to get the two pipes to come together nicely as they now interfere.

03-30-2015, 01:09 PM	#2
DieselDakota The Newbie Join Date: Nov 2012 Posts: 29 Rep Power: 0	I went back out after supper. I managed to close up the gap pretty good on the one runner by fooling around a bit, still a bit of a gap but not nearly as bad. I didn't manage to stretch the other runner much better so I fooled around and centered it. From the start I knew I would be laying a ton of weld between the pipe and both flanges, this will be because I will grind the flow path smooth and I will have to build up at least past were I intend to grind, this is why I didn't care a lot about the flange fitments, I would have liked them better but I was getting tired of just wasting time. So once I was happy with all the fitment I tacked everything together so that I could do a test fit tomorrow with the turbo on the car. here is some pics. I really should have wire wheeled it before tacking it up, it looks so bad now. I'll have to make sure not to forget that when it comes apart for the final welding. I'm pretty confident it will fit just fine, now I'm trying to find some welding friends who will help me with the important bit for some beer etc. looks good after some machining. not pretty but it will be strong and work good. the turbo is going into a pretty tight space and it was hard to test fit, I was fairly confident it wouldn't fit after machining. I was however happily surprised. it fits and now its onto fabricatinging the exhaust.

03-30-2015, 01:15 PM	#3
DieselDakota The Newbie Join Date: Nov 2012 Posts: 29 Rep Power: 0	Alright this brings me up to modern day. I should win some kind of award for the smallest scroll bar ever in a build thread. 1. Currently I need to build a bracket to hold the wastegate canister as the one that came with the turbo won't work because of how the turbo is clocked. 2. I still need to make up oil lines and coolant lines to the Turbo. 3. I need to buy a wideband, currently looking to find a good canadian source for the innovate motorsports 2 in 1 boost and wideband kit. 4. I need to fab ub the downpipe and midpipe as well as modify my catback, this is waiting on the 3"GT vband flange for the turbo that I mistakenly thought was the same as any 3" vband flange. 5. I'm trying to piece together a fuel system, I have a friends system with some old EV1 1680 secondaries and the stock 550 primaries. this will be my backup plan depending on what else I can piece together. I'm also still trying to find a cheap used datalogit.