Cast manifold and dump fit WRX turbo to 1.8L MX5

[omx500]

Those pictures of the brackets in front of the radiator were pretty bad. Hope these arrows make it a bit clearer. They are taken from the front of the car through the 'mouth' in the front bar. I should have taken a photo of the bracket installed before the intercooler went on. Next time

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[speed]

I'm following with interest

Had to moddify my heater return pipe in the same way.

Is that a stick on front number plate?

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[omx500]

I'm following with interest

Had to moddify my heater return pipe in the same way.

Is that a stick on front number plate?

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Thanks for the interest Speed. I have hit a bit of an issue. Photo's coming. Yes that it a stick on number plate, or more accurately, a sticker made to look like my number plate. It is a pretty good likeness in size and colour if not font.

[omx500]

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As usual I have tried to push things and the compressor cover on this GT2860RS is heaps bigger than even the GTPS01 TDO5. I think I can cut the lip of the frame rail and fold it down, as per the Flyin' Miata turbo kits, but there may be another way, which I am working on. Below is another view of the extent of the fouling. The turbo almost bolts on to the manifold, but I am severely limited in my option for spinning the compressor cover as it is just too big everywhere.

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[speed]

I have the same issue going from my t25 to t28. I'm hesitant to cut and fold the lip as I know my engineer will not like it.

Here's the t25 with a clocked turbo.
Crap photo but you get the idea.




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[NitroDann]

Have you tried clocking the outlet vertical?

[omx500]

I have and it is not really much better with this particular compressor cover. I have my eye on a slightly different manifold. Like speed I am also worried that a cut and fold of any sort on a frame rail will upset engineering. I already had my supercharger, brakes, wheels, seats and roll bar engineered. Not looking forward to doing it again and want least possible hiccups.

[speed]

I can't say for sure bit suspect if welded after the cut and fold it should pass. I just didn't want to go there.. yet.

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[Sean]

I have the same issue going from my t25 to t28. I'm hesitant to cut and fold the lip as I know my engineer will not like it.

Under the old system I had cut tabs like that off cleanly, welded up along the resultant edges, finished nicely and painted body colour with zero concern by the engineer or anyone else. If it looks sensible and isn't removing any structural integrity you wont have an issue - correct me if I'm wrong but that piece is simply a spot weld and some sealer?

Another option would be to carefully remove some material from the turbo housing itself - it looks pretty thick in that front housing around the problem area?
Third option or though (but measure twice before getting too serious) would be to mill some off the face of the manifold flange and turbo flange - we are only talking mm, but everything can help, milling it off at an angle to point the turbo a more diagonally upward may get you past this problem, but you'll need to consider the dump fitment and route as well as if you have those few mm to spare inbound of the turbo...

Interesting build man - as much as I'm typically a fan boy of the FM and AVO kits, it's cool to see a bunch of people taking different approaches in recent times and the various ups and downs of each approach and commonly available parts.

[omx500]

Hey Sean. Thanks for your input. Every option you have put forward has merit. I am away on holiday for a week but when I get back will add up all the mm to see what space I can generate. I should reiterate that any of the stock Subaru turbos that the manifold was designed for will fit without any issue with the frame rail. I just had to go a little bigger (and I really wanted a bb core).

[Lokiel]

NitroDann catch can - you're doing it WRONG:

[speed]

NitroDann catch can - you're doing it WRONG:

Lol. It was a pic from my thread.
Was the quickest way for me to show the minimal clearance between the turbo and rail.

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[omx500]

These eventually got to my house, after being delivered to the same number house in an adjacent street by TNT.

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[omx500]

The 'kit' I purchased also came with a brace for the turbo, brace bracket and long front pipe. There were also a few bolts, mostly for the brace and bracket.

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[omx500]

Seeing photos of this manifold online made me think that for the slightly larger turbo I was trying to fit, the more top mount style would pull the compressor cover away from the frame rail, move the inlet for the compressor cover above the power steering pump, and may also give more flexibility to rotate the compressor cover to gain optimal piping routing and easier restoration of wastegate function on the clocked compressor. Though it was obvious the top of the turbo would be leaning in closer to the engine, I hoped that it would not foul on my laboriously constructed coolant reroute tube.

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Well the coolant reroute was going to need a bit of work, but looked fixable, if the rest of the instal was an improvement to make it worthwhile.

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Turned the core to get the oil drain facing downward, then turned the compressor cover to where I wanted it and fitted the wastegate (which has a convenient slotted bracket allowing fine tuning)