How to turbo your NA for $2000.

[NitroDann]

So continuing with this flange..

Trace a rough stencil.


Double check you have a hole saw that matches the turbo.


Connect the edges with straight lines, this will be cut with an angle grinder.


Looking ok.


Tidied up with sandpaper.


Now it looks alright.


Tonnes of spraypaint, note that I took the turbine housing off to do this.


Now we have a flange shape, we can holesaw the centre out and build a downpipe.


Dann

[Aussie Stig]

I think Dann should have a regular segment, "Tool Time"

[NitroDann]

Holesaw your holes.





Angle grind the centre out.



Tidy with the die grinder


Been flat out on the phone and stuff today, Ill get some good updates tonight.

Dann

[NitroDann]

So a box of bits arrived this arvo




So Ive tacked the turbo to the manifold, for some test fitting and the downpipe build.


The vice will be used like this to shape the pipe initially.


This little guy is the water return for the in cabin heater, it always gets in the road of a good downpipe.


But with some gentle persuasion, it easily bends away for a little more clearance, this is standard practice on turbo NAs.


I dont suggest consulting the warranty handbook for the vice before doing this, it wont help


I know its ugly now but let me weld it and tidy it and away we go


Dann

[lightyear]

If you are doing this more often. It would pay to get 20-30 laser cut. It really doesn't cost much. I get all my hardtop brackets laser cut. I think they cost under $20 each. In mild steel like you have, it would probably cost around $10 ea. It's good to just open a draw and pull out a flange ready to go.

[NitroDann]

I have boxes of flanges but this one is a fraction different than a 25/28 one... Such is life.

And Ive been doing this too long to make mistakes like this

Ah well, whats half an hour out of my life?



Dann

[Old Dude]

I think that's a great idea mate, straight through system out the bonnet no need for any further bends, saves on cost and back pressure
Cheers
Dale

[MrRevhead]

A slight modification can make that into a bonnet wastegate pipe like my mate's R31... lol

http://www.facebook.com/video/embed?video_id=10151075627754351

[NitroDann]

On a phone so didnt click the link but... Tractor flapper?

Dann

[Gladiator]

Great thread Dann. Bookmarked for future reference.

[ivan]

This has been playing on my mind since I started reading this thread. My car is pretty much dedicated to trackdays and I've been wanting more power for a long time. i'm after drivable power with no lag and still want a reliable car that can run all day long. This set up seems perfect for what I want.

Im guessing price of megasquirt and tune are on top of the $2k?

Would adding an intercooler make the engine more reliable? Or is it more for adding power?

[NitroDann]

It includes the megasquirt, installed, and with a basic safe street tune that will get him around town for a little while until he finds time to take the car to the dyno.

Dann

[Apu]

Ivan, brand new TD04 for sale! Can bring to next CC day or drop off at Adrian's...only 5 min from my place!

[NitroDann]

Big update time.


Tacked a couple of bends to the downpipe, this routing gives a LOT of clearance for working on the car.


Here is a reducer cut in 2, this was 3>2. Now its a 3>2.5 and a 2.5>2.


This demonstrates how it will work to bolt this to a stock 1.75" system, this car has a 2".


Nice flow.


Performance is all about the details, the die grinder is used a LOT when doing custom piping.


From top to bottom, 2" flange, 2>2.5" 316SS reducer, 2.5" SS straight, 2.5x6" SS flex pipe-double braid for flow.


Tacked to the rest of the downpipe. This took 2 goes to get the flanges lining up to the millimetre.


Nice straight path.

Installed, tucked up nice and high, 100% above the frame rails.


Getting started on the crossover pipe.


Path. Nice and short.


Throttle body side started.


How it all sits on the car, needs another 2.5>2" reducer and AIT bung for the MegaSquirt ecu, and the tube for the Idle Air Control (IAC valve).


Dann

[NitroDann]

Dann