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Old 08-07-2011, 09:53 PM   #1
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Default WittyWorks Fabrication 3 week build thread

Figured I'd post up updates on here over the next three weeks while i get my car running again. I start school on August 29th, so i have three weeks to get everything finished. I'll try to take pictures of everything along the way.

Setup is:
-Custom short tube manifold
-EFR 6258
-Precision 600 hp IC
-DIYPNP

Those are all the parts that are definitely being used.

Will also have a full 3 inch v band exhaust.

I have the manifold all tacked together and I am going to final weld it tomorrow. Manifold is completely stainless steel, using flanges you can find for sale on my website.





Once I finish the manifold, next steps will be to mount the intercooler and make my 1 piece ic piping and downpipe/exhaust.
I will probably run just straight exhaust for a couple weeks, unless i finish early and have enough time to put the biggest magnaflow on there.

Things i need to do:
Fuel Injectors:
I want the id1000's and I plan to run e85 in the near future, but my block is still stock and my entire fuel setup is still stock.

Finish DIYPNP:
I have the whole first phase done, now i need to wire all the jumpers and i'm kind of lost at this point, wil probably work on this next week.

Figure out coolant line situation:
A coolant reroute, probably the begi reroute, might be added to the list. I think this will give me better locations for coolant feed and return, as well as a place to hook up the water temp gauge sender.

I think that is all for now. I'm also not sure about how to hook up the EFR electronic boost control, so i might be running straight wastegate for now.
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Old 08-07-2011, 09:58 PM   #2
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Gawd...nice manifold. Your 6258 should spool like mad. Can we get some collector shots pretty please???
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Old 08-07-2011, 11:48 PM   #3
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kinda wish i would have done mine like this..
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Old 08-08-2011, 01:21 AM   #4
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Ya yank, i like this design because it keeps the runners short and won't need a turbo crane for track use. Also, placement is hard with the efr due to the added width of the wastegate. It's tough to get the turbo mounted low, but this will work pretty good I think. It was difficult to make the collector area though, cutting the weld els correctly took some time. I'll get more pictures and inside shots tomorrow
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Old 08-08-2011, 09:49 AM   #5
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Lookin good! Guess i wont' be selling my 3/8 flanges
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Old 08-08-2011, 10:06 AM   #6
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those thin cuts look like they will be part of one big weld later on. you will 100% want to purge that if you typically dont do it on your manifolds. the thin peice will heat up fast fast and precipitate at a fast rate.

looks good though!
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Old 08-08-2011, 01:02 PM   #7
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Oh don't worry I'm definitely backpurging it. I backpurge all the Stainless I do, because the gas really isn't that expensive in the long run. I really didn't want to have those thin pieces, but I cut the two merge pieces too short. When I make the next one of these, that small piece will be eliminated.
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Old 08-12-2011, 02:29 AM   #8
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So like almost all builds, has been going a little bit slower than expected. I have all the manifold tubes welded now and the ovals pressed, so now I just need to weld the flanges on.
I will be ordering on Monday:
id1000's (from horsepowerfreaks if they supply spacers)
autometer phantom boost gauge
possibly begi reroute

Here is a couple weld pictures and a collector shot that was asked for.





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WittyWorks Fabrication 3 week build thread-photo39-2.jpg   WittyWorks Fabrication 3 week build thread-photo40.jpg   WittyWorks Fabrication 3 week build thread-photo41.jpg  
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Old 08-12-2011, 12:03 PM   #9
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Subscribing!

HP goal?
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Old 08-12-2011, 01:42 PM   #10
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collector turned out well!
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Old 08-12-2011, 01:47 PM   #11
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Thanks! Yah being a perfectionist it's not perfect but I'm happy with it.
Fae- power goal is 250ish at this point which I think will be achieved at 10-12 psi. Trackspeed motor will be bought when the money is available, but that could be a while, probably a year off due to college student.
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Old 08-17-2011, 03:17 AM   #12
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Update: I have ordered id1000's, two more necessary vibrant v-bands, and bigass magnaflow muffler. Still need to order begi coolant reroute tomorrow and get water and oil lines made at local shop (san jose brass).

Manifold is completely welded now, needs about 45 more minutes of smoothing out the runners and will be done, pictures of completed manifold soon.
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Old 08-22-2011, 04:00 PM   #13
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Well three week build turned into 1 week build basically. Girlfriend is moved into college now so I will immerse myself into finishing the car. Have a lot of work to do, but the manifold is done.

Big Update tonight for everyone.
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Old 08-22-2011, 04:26 PM   #14
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You know you've only got 6 days to complete this in the original 3 week time frame?
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Old 08-22-2011, 05:31 PM   #15
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haha. builds always take longer than you think.
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Old 08-23-2011, 10:07 PM   #16
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Quote:
Originally Posted by wayne_curr View Post
You know you've only got 6 days to complete this in the original 3 week time frame?
Quote:
Originally Posted by shlammed View Post
haha. builds always take longer than you think.
I know, but this build will be done by sunday. I worked until 1230 yesterday to get enough done for my satisfaction.

So, manifold and turbo are in in their final location but only mocked up:



Id1000 injectors are installed:



And bigass intercooler is mounted:







This 600 hp precision intercooler is just barely too big to fit easily into the miata. In one picture you can see I had to take off some material at the top two corners to get the IC has high as possible. I really should have gotten the 350 hp one, this is definitely overkill for my car right now. Oh well, eventually it will be used to its full potential.

Today I took sort of a day off, i picked up all the rest of the loose ends needed to finish the build. I got all the fittings and lines for oil and water feed, my air filter, a flex section for the exhaust, and a spare 02 bung and IAT bung in case i can't find the ones in my garage.

Tonight I'm going to spend a couple more hours working on the diypnp, which is going to be the most difficult part of finishing my build on time.

Intercooler pipes and Exhausts are easy for me, I should be able to get most of the intercooler pipes done tomorrow, working from 9-1, and i am planning to work all day long on thursday to get the ic pipes done and the exhaust done.

Also, while mounting the IC, I had to take off some of the plastic under ther front bumper where the stock undertray bolts onto. This means that I'll have to make a new undertray, but that will probably happen after I get the car running. I'm just going to use a large piece of 1/16-1/8 inch aluminum and make a nice one piece undertray for below the engine compartment.
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WittyWorks Fabrication 3 week build thread-photo41-1.jpg   WittyWorks Fabrication 3 week build thread-photo42-1.jpg   WittyWorks Fabrication 3 week build thread-photo44.jpg   WittyWorks Fabrication 3 week build thread-photo45.jpg   WittyWorks Fabrication 3 week build thread-photo43.jpg  

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Old 08-28-2011, 07:25 PM   #17
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Well what can I say, it's not going to be done today. I'm pretty disappointed because I have enough time to finish everything, but I lost a piece that I need. I can't seem to find where I put the v band clamp and flange that the efr uses.

Without that clamp and flange I cant build the downpipe and can't really do the rest of the exhaust. The worst part about it is that its a special "narrow" v band clamp and flange which i will have to order and have shipped to me tomorrow. As long as the clamp gets here by wednesday or thursday, car will be done on thursday or friday.

As far as the rest of the car goes, both cold side and hot side intake tubing is done, intercooler is mounted, ecu is done and hopefully working(fuel pump turns on and connects well with tunerstudio), and I have all the oil and water lines setup. Turbo is mounted to manifold, it can all fit in as one piece which is nice. I really just have to do the exhaust then button up a the rest of the loose ends.

Oh well, one more week not driving it won't be horrible.
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Old 09-07-2011, 12:34 PM   #18
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Started on the exhaust yesterday when i had a couple hours to work. It's safe to say that a 21 unit course load puts a damper on my time to work on the car.

I did get a lot done though yesterday. I got the entire downpipe tacked togetehr to the flex pipe, and it only took me 3 bends! it is really clean looking. I should have some more time to work on it on thursday, i'll see how much i can get done and try to take some pictures of how far i get.
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Old 09-09-2011, 01:37 AM   #19
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I got the downpipe all tacked together and mocked up today, and it looks sweet. I managed to only need three pieces, which is much less pieces and welds than my previous setup. Heres a picture of my downpipe and test pipe all mocked up:



Test pipe is 2 feet long to accomodate any future resonator or cat if i want one.

The last big accomplishment i need to make is to mount the muffler, and finish the exhaust. Hopefully will be finished by next weekend, I'm busy this weekend at a wedding out of town.

I'm really missing driving this car, can't wait for it to be "done" for a while.
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Old 10-04-2011, 01:48 AM   #20
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Finished the next big hurdle. Everything is hooked up except for the oil feed line to the turbo, which i need to prime before starting.

Exhaust is completely tacked together, along with all muffler and exhaust hangers. I have about two more hours of welding to weld everything up, then just installing the exhaust and hopefully starting it up!!



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