downpipe - Please excuse the mess. Here is my ghetto fabulous downpipe tack welded for test fit. I used exhaust parts laying around in the garage.
downpipe completed - I painted it with high temp spray paint to help against rust. It is actually a two-piece design that are joined using a slip joint.
downpipe installed - I will probably go back and heat wrap the downpipe.
and here it is under the car - It bolts to the stock cat.
O2 sensor - I ran the wideband through the shifter hole and plugs into the downpipe.
Intercooler - I went with 2.5" cold side. The coupler on the throttle body is a 45 degree bend connected to a 90 degree aluminized steel pipe. You can see I drilled a hole for the IAT (intake air temp) sensor. You want the sensor to be close to the intake manifold. Basically it should read temps that the engine is being fed. I also plumbed the ISC valve into the charge piping here.
At the bottom of the pipe a 45 degree coupler is connected that points down. I used a straight piece of pipe and immediately connected a 90 degree coupler.
Cold Side - Under the car now, I used a 90 degree coupler and a 90 degree pipe. I used a 90 degree reducing coupler to fit the 2" inlet on my intercooler. As you can see I cut a hole in the plastic shroud. This completes the cold side.
I replaced the pipe above with a BOV.
Intercooler - Here's how I mounted my 28 x 5.5 x 2.5" ebay intercooler. I used 1" aluminum strips, bent it into shape I wanted and cut it to size. Since I have AC and power steering it was a huge pain to get it installed.
Drier - You have to bend the drier as far to the left as you can. To accomplish this you have to remove the metal drier holder that's connected to the condenser.
Intercooler - Here's how I mounted the intercooler on the bottom side. I used 1" wide aluminum strips and bent it into the shapes I liked and bolted them down as shown. The intercooler just barely fits the stock plastic shroud.
Hot side - I decided to go with 2 inch hot side due to the space limitations. There is literally nowhere to route with PS and AC in the way. I used a 90 degree coupler from the intercooler.
hot side - I used a flexible radiator hose for the charge piping! It is 53224 Goodyear 2"x24" hose. I also had to replace the stock lower radiator hose with a Dayco 1 1/4" x 23" radiator hose for extra space.
hot side - Here is where the flex pipe enters the engine bay.
From the radiator hose charge pipeing connected is a 90 degree coupler, then a straight pipe, then another 90 to the turbo outlet.
Air intake - I used the turbo stock intake arm and used a 45 degree coupler to a short piece of piping. It's a K&N filter RU-4950. It is 2.5" inlet 6" base, 5" diameter top, and 5.5" tall. It fits but just barely. If you are wondering, the filter mesh is bent because I still had it wrapped in plastic (silly me) and started the engine and the whole filter collapsed!