Turbo Build Diary
03-16-07, 08:37 PM
#38
Driver
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Join Date: Feb 2006
Location: New Jersey
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It would be nice to have a detailed list of all the parts you used because I would love to do the same. I was gonna go with the srt setup but if i can bild my own kit I would rather do that. Great writeup by the way thanx!
03-17-07, 02:47 AM
#40
Mar 15, 2007: A bunch of cutting and test fitting.
- Finished routing heater core tubing and removed kinks.
- Removed transmission cooler line tie downs.
- Test fit drain flange.
- Routed sensor wires out of the way.
- Mounted vacuum sensor out of the way and replaced tubing.
- Cut front subframe metal piece to enable clearance for intercooler piping.
- Grind down jagged metal and apply touch up paint.
- Cut plastic cover so intercooler piping can go through.
- Mocked up a few intercooler pipes.
- Cut a hole in the engine bay for intercooler piping to be routed down.
- Cut intake tube.
- Put everything back together.
Finally got that coolant hose on there correctly. Hose clamps installed. Also, note the one clamp in the middle. It's there to prevent the pipe from kinking.
That white wire on top is my Zeitronix data cable. It goes inside the car for my gauges. Electronic readout tucked in the corner! EGT, Boost, and Wideband O2.
Pix of my interior below with a close up of the Zeitronix unit.
Removed the clamps holding the transmission cooler lines. They will have to be moved out of the way to drill the oil pan for the return line.
Close up of my oil return flange. Function7 high quality unit, not a cheap knockoff. When it comes to oil supply for the turbo, DON'T cheap out!
This is where the oil return flange will go. I'm drilling/installing that tomorrow when my tap and die kit comes in.
Bolted the vacuum sensor module to the chassis so it's not hanging around. It's bolted on the air box with the stock setup.
I didn't want that big long hose to be dangling around so I replaced it with a pretty blue hose...heh.
Note: I didn't take a pic, but I had to hack off part of that pipe that was sticking upwards.
Tucked sensor cables further away from the turbo. There are 4 bolts to remove the bracket. Check out previous pictures to see how it was in factory configuration. Before I rerouted that cable, it was sitting about 1/2" away from the turbo!
- Finished routing heater core tubing and removed kinks.
- Removed transmission cooler line tie downs.
- Test fit drain flange.
- Routed sensor wires out of the way.
- Mounted vacuum sensor out of the way and replaced tubing.
- Cut front subframe metal piece to enable clearance for intercooler piping.
- Grind down jagged metal and apply touch up paint.
- Cut plastic cover so intercooler piping can go through.
- Mocked up a few intercooler pipes.
- Cut a hole in the engine bay for intercooler piping to be routed down.
- Cut intake tube.
- Put everything back together.
Finally got that coolant hose on there correctly. Hose clamps installed. Also, note the one clamp in the middle. It's there to prevent the pipe from kinking.
That white wire on top is my Zeitronix data cable. It goes inside the car for my gauges. Electronic readout tucked in the corner! EGT, Boost, and Wideband O2.
Pix of my interior below with a close up of the Zeitronix unit.
Removed the clamps holding the transmission cooler lines. They will have to be moved out of the way to drill the oil pan for the return line.
Close up of my oil return flange. Function7 high quality unit, not a cheap knockoff. When it comes to oil supply for the turbo, DON'T cheap out!
This is where the oil return flange will go. I'm drilling/installing that tomorrow when my tap and die kit comes in.
Bolted the vacuum sensor module to the chassis so it's not hanging around. It's bolted on the air box with the stock setup.
I didn't want that big long hose to be dangling around so I replaced it with a pretty blue hose...heh.
Note: I didn't take a pic, but I had to hack off part of that pipe that was sticking upwards.
Tucked sensor cables further away from the turbo. There are 4 bolts to remove the bracket. Check out previous pictures to see how it was in factory configuration. Before I rerouted that cable, it was sitting about 1/2" away from the turbo!
Last edited by JeffTsai; 03-17-07 at 03:15 AM.
03-17-07, 02:48 AM
#41
This was probably the most dreadful part for me. I was really hesistant to cut into the car, but I had to. I have 3" intercooler piping so it wouldnt fit with that metal piece in the way. I had to trim it down a bit as you can see.
Cutoff airtool in action.
LOL...that's me with the goofy safetly goggles and noise cancelling headphones. Only reason I'm showing this pic is because it's VERY important you use protection. When cutting I could feel a bunch of the metal sparks hitting my face. If I didn't have the goggles my eyes would of been screwed. The cutting noise is pretty loud too, so if you plan on keeping your hearing 20-30years later I recommend you use some kind of hearing protection.
Cut complete.
A picture of the other side showing how much that metal piece blocks.
This is right after the cut. The metal edge is very sharp and jagged.
I used the dremel and sanding wheel on my electric drill to smooth out all the jagged edges. I also use some touch up paint to cover up all the exposed metal so it won't rust.
03-17-07, 02:49 AM
#42
I inserted one of the intercooler pipes to see where I need to cut the hole in the plastic cover.
Electric drill + hole saw = very clean cut.
See, I told you.
Another shot from the other side.
I bought this huge chop saw to cut up the intercooler piping.
This thing is a bad azz **** lol. It went through that pipe in like 5 seconds.
03-17-07, 02:49 AM
#43
After cutting the pipe, there are a few jagged edges.
Use a dremel and drill with sanding wheel to smooth out the pipe. You MUST smooth it out! If you don't the sharp metal will cut into the hose couplers and cause them to fail over time.
Pipes mocked up. Too lazy to finish the lower intercooler piping today. I'll do that tomorrow...heh.
Cutting the big intake pipe. The filter I'm using is huge so I have to hack this pipe up.
I forgot to take pix of this step. Anyways I just cut a hole there to route the intercooler piping down. I lined it with some chrome trim lining so it looks better.
End of todays progress. More to come tomorrow!
Oh yeah, for those of you asking about parts and such. I'll have a detailed writeup of everything when I'm done.
I always work on the car at night. I think my neighbors hate me lolol. Drilling, sanding, grinding, and cutting at 3-4AM = not so happy neighbors
