NBoost

Any updates on this?

wittyworks

iTrader: (6)

Not many updates turbo wise, but I got the car back together and passed smog. Installed a new Koyo Radiator and Progress sway bars, and replaced the malfunctioning thermostat. Car is on the road and driving beautifully right now.

As far as turbo goes, I am waiting on a machinist friend to CNC the four collector pieces for me. I could try to make them myself with my chop saw, but that trial and error process to make them perfect would take a lot of my time. I am just going to wait until he has time to CNC them perfectly for me, which will give me a good foundation to build the rest of the manifold up to the exact CAD drawing.

Hoping to have forced induction in 2015.

NBoost

Very nice. CNC is definitely the way to go. Get someone to write some good/timely G-code for it as well and it might pay off should you ever decide to produce several to sell. EFR's are going to be the future of boosted NC's I would bet.

wittyworks

iTrader: (6)

I haven't seen them in person yet, but the collector pieces are done and I have a picture. They look like they came out pretty good to me! Hopefully I will have some time soon to work on the manifold. Project is going sloooooow but it will get finished eventually.

wittyworks

iTrader: (6)

I have some updates with pictures! I finally found some time to work on the manifold this weekend, and I think it came out pretty nicely. This was the first manifold I used a real collector on, and it was so nice to work with. I'm planning to finish up the final welding over Thanksgiving weekend.

Pics:










The short list for things to do is:

Finish welding manifold

Clutch install (FM Happy Meal)
Motor mount install (AWR 70 durometer, hope I don't hate the NVH)
Install new brakes, just because (goodwin 6 pot front, fm 4 pot rear)
Install new braces to make sure everything turbo fits with them

Hot side tube routing to IC
Turbo intake tube routing
Cold side tube routing to intake

Turbo plumbing

Downpipe
Exhaust

Gauge cluster (Undecided on AEM or Stack gauges, leaning toward AEM because I have had good experiences with them previously)
Gauge plumbing

Install new fuel injectors

Tuning

I think that covers the gist of it. The intercooler end tanks will be another large probably slow fabrication job for me, since I am making the end tanks from scratch. I also need to figure out details on the turbo plumbing, and figure out who I am going to use for the tune. Moving slowly, but I am very happy to have gotten this far on the manifold this weekend.

EO2K

iTrader: (37)

Ooo! Its pretty! I love it when this thread gets updated.

triple88a

iTrader: (2)

You going to be able to get a good weld in the middle of the pipes?

wittyworks

iTrader: (6)

I assume you mean at the center of the merge collector? Yes, that would be difficult to weld with everything in place.

Once I had everything tacked and place and I knew that the manifold design would fit, I cut the collector back out and I am finishing the welding and porting of the collector first. I am also going to individually weld the portions of the runners that will be difficult to access if the manifold was all put together (only one inch long area). Once the tough to reach places are welded, I will put it all back together and final weld the rest of it on the fixture as one piece. Then I will use a die grinder to smooth out the header ports as necessary.

Collector is about half way welded right now. I will be taking next Wednesday off of work and may be able to have the entire manifold welded up by Weds afternoon.

triple88a

iTrader: (2)

Yes thats what i was asking, thank you for explaining.

wittyworks

iTrader: (6)

So I have good news and bad news.

Good news is that the manifold is done.

Bad news is that the manifold doesn't fit. Apparently I thought I had a bit more space around the collector. The collector portion of runner 2 is contacting the body panels in the engine bay.

Plan is to go faeflora on this now. Fortunately for me, I don't think I'm completely incompetent with a sawzall, and I know how to Tig weld. I could redo the entire manifold, but that seems like more work to me at the moment.

I may make some progress on this in the next few hours. If I do and it looks decent I'll post some pictures.

aidandj

iTrader: (5)

You need a large kinetic motivator. That should clear some area.

wittyworks

iTrader: (6)

I don't have much space to swing a kinetic motivator with much gusto.

wittyworks

iTrader: (6)

Alrighty. Engine bay "modification" went pretty well so far. I got everything cut out and made some cardboard templates for the filler panels. Didn't have time to cut or weld the panels today, but I am very happy that the cutting went well and the manifold fits now! Here are some pics of where I am at now.

Manifold:


Hole cut:


Hole with cardboard filler:


Manifold bolted in place: