Install from Hell.....New pics of "Completed" install

[tom04841]

This is the very short edited version. Good thing because i did ALOT of swearing......I'm going to HELL. Oh where to begin?

Lets start with the manifold.....ss autochrome tubular. Don't cringe.....it is braced...big time. For $80 shipped, i can't complain AT ALL. Fit very well, just had to grind down the drivers side corner...no big deal.

Now for the turbo....GT35R. Very nice piece . Everything looked kosher untill i went to bolt it up. The turbine and compressor housing where hitting the block...i believe it is the hump where the balance shaft is. The turbine flange met the mani flange at the forward edge, but the block side had a gap about 1".

Out comes the cutoff wheel. I cut a 1 1/4" wedge out of the front side of the manifold collector, heated the only weld left (block side) and beat the flange to get the right angle for the turbo to clear the block. Welded it all back up. Then ground down the burrs on the inside of the collector. 2 hrs later, the manifold and turbo where ON

But wait, I still have to fab the O2 housing. It was such a tight fit, that the flange that meets the downpipe is touching the oil filter...but its on. So now, until I figure something else out, I have to unbolt the front part of the downpipe to do an oil change

Next is the Tial wastegate. Um yeah.....it cant go on because the oulet comes the drvers side of the collector and points right at the power steering pump. WTF Looked everywhere for the right size pipe in the shop....nothing to be found. I like my power steering, so removing it isn't an option. So i just made up a block off plate really quick and bolted it on until i can make a little 90* bend to place the WG at a different angle. I will just baby it until its done.

Now to the FMIC. Went with longer route piping because i war exhausted and it was by far easier. I have to say, that this was the easiest part of the whole install. Everything went as expected.

The entire process took 10 hrs to do......i was tired as hell when done. The gains in the end will be entirely worth it though.

 

[Raph]

pics?

custom frabrication is where its at,its such a great feeling after youre done..it makes up for the PITA factor

 

[maximumbob]

Glad you got it on. We defnitely need pics too.

 

[tom04841]

I said to hell with it and took off my ps pumpso i could put the WG on

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Putting in map sensor and ait sensor tomorrow along w/ my speed density chip, so no recirc tube required

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Shot of the FMIC. bye bye bumper support. Still have to cut the front bumper to increase air flow thru the IC

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Another shot of the bay...its dirty. Still waiting on getting my slim fans. Good thing i only have to drive 2 miles to work with no lights

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[spinz4]

Lookin good!

 

[Gary 420A RS]

you need a new radiator. especialy with all the mods your doing to this. youll regret it if you dont.

 

[Flash]

So you did all that just to save a few buck on a manifold? I don't think it's worth cutting and grinding to make everything fit, just to save a few dollars.

 

[tom04841]

So you did all that just to save a few buck on a manifold? I don't think it's worth cutting and grinding to make everything fit, just to save a few dollars.

NO! I did it because i had everything ripped off the car. I wasn't about to put it all back on and burn the shit out of my hands again to take it off when I had the money to get a different manifold.

Even though it didn't fit perfect at first, the 2 hrs i spent to alter the manifold was worth the savings. Especially since i would have spent time bracing it anyway.

On a side note, the ORIGINAL turbo bolts came out with ease after a 40 minute drive to my bros shop......burned my hands up, but atleast none snapped.

 

[Ky91Tsi]

Why is there a proportioning valve mounted in that spot.....isnt it supposed to be on the firewall.....did you just delete the ABS?

 

[Flash]

NO! I did it because i had everything ripped off the car. I wasn't about to put it all back on and burn the shit out of my hands again to take it off when I had the money to get a different manifold.

Huh? You got that manifold and did all that work because you didn't want to burn your hands?

 

[tom04841]

Why is there a proportioning valve mounted in that spot.....isnt it supposed to be on the firewall.....did you just delete the ABS?

Yes i did. It was much easier to tweek the lines than to run all new.

Huh? You got that manifold and did all that work because you didn't want to burn your hands?

AGAIN! That and i just wanted it on. I was just very frustrated and expected it to all just bolt on. Oh well. I wasn't doing anything else last night anyway. So i spent a couple hrs making it fit right. Now that i'm not exhausted and looking back on it, it was worth it.

, the top end is SICK!!!