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Old 03-14-2008, 02:31 PM   #1
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Default another DIY, 1995 1.8L turbo install

After a long delay, my turbo install has begun. My wife's back in school, working on her doctorate, so living on one income has slowed down my progress.

I'm using a DIY manifold/downpipe/volvo t3 turbo/saab intercooler that I purchased from a member here a long time ago. I picked up one of the 2" pipe kits off of ebay and I've ordered some misc. silicone reducers and clamps from siliconeintakes.com. I ordered up my oil lines and misc. fittings from anplumbing.com.

I don't have many pictures yet, but here are a couple of progress pictures that I have uploaded to the web:




I prefer the simplistic over the radiator pipe routing, it has required lowering and tilting the radiator back plus some trimming on the support brace. I bolted in a piece of angle under the brace to hopefully add back some rigidity.



This isn't my every day car, so I'm not too worried about the filter in the cowl. I had a hole there from my DIY randal style air intake, so I decided to use it for the turbo intake too.

The manifold didn't have an EGR connection, so that is gone too. I will replace this with a piece of stainless at some point, but it will do for now:


More to come, I'm waiting for a compressor housing gasket to come in before I can bolt everything up and push the start button.
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Old 03-14-2008, 03:13 PM   #2
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Nice can you take more pics. i want to see were the oil line should go and all other hose's
i have a 1991 but it should be some what similar

thanks
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Old 03-14-2008, 03:16 PM   #3
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that EGR plate might leak. doesnt look like it will hold well.all in all, looks good ^^
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Old 03-14-2008, 03:21 PM   #4
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Originally Posted by badboy88000 View Post
that EGR plate might leak. doesnt look like it will hold well.all in all, looks good ^^

too much boost is going to blow the welds, right?
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Old 03-14-2008, 03:41 PM   #5
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the original egr gasket is under there, I don't think it is going to be a problem. The hole into the manifold isn't very big.
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Old 03-14-2008, 03:58 PM   #6
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That plate isn't going to leak. If it does throw some RTV on it. Not a big deal.
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Old 03-14-2008, 04:03 PM   #7
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Chad, you have no idea what boost does to EGR ports!
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Old 03-14-2008, 04:05 PM   #8
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I know i know, hell i'm running my EGR tube with a welded end with no gasket and it doesn't leak. quitcherbitchin
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Old 03-14-2008, 04:20 PM   #9
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I like it.
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Old 03-14-2008, 06:53 PM   #10
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hooray for DIY job, looks great...

i know you dont give a **** about what i would do different, but im not digging the intake pipe...other than that, cant wait to hear her running
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Old 03-15-2008, 06:48 AM   #11
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Looks good. I've been thinking about moving my intake the cowl myself...
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Old 03-15-2008, 04:55 PM   #12
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Looks great! Good luck buddy!
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Old 03-17-2008, 01:46 PM   #13
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Made a little bit of progress this weekend. All the intercooler pipes have been sorted out, but I neglected to get a photo before we took things apart to do other parts of the fabrication.

Oil pan drilling and fitting. That leaky front seal is going to have to be replaced at some point...



Here is the blow off valve and the bracket that I made for it. I'll be polishing the bracket to hopefully make it look a little nicer. The idle air hose will attach to the copper piece that is hanging down from the middle of the hose.


Air intake temperature sensor in the pipe between the intercooler and the throttle body. Luckily, the tap for the oil pan was the same size!
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Old 03-17-2008, 01:48 PM   #14
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Quote:
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I know i know, hell i'm running my EGR tube with a welded end with no gasket and it doesn't leak. quitcherbitchin

lol you guys crack me up.
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Old 03-17-2008, 03:10 PM   #15
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Mmm, I like the position for the air filter. Lets you hear the turbo spool really well!
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Old 03-17-2008, 03:43 PM   #16
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Kickass DIY work!
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Old 03-17-2008, 04:50 PM   #17
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Quote:
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Mmm, I like the position for the air filter. Lets you hear the turbo spool really well!
For sure. I have mine set up the same way, even looks like the same filter from the picture, and it is loud, much louder than the stock (for now) exhaust.
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Old 03-17-2008, 04:51 PM   #18
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Originally Posted by ZX-Tex View Post
For sure. I have mine set up the same way, even looks like the same filter from the picture, and it is loud, much louder than the stock (for now) exhaust.
With MS, I deleted the afm, so the intake is right at the turbo inlet now. I miss the wooshing noises. :(
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Old 03-20-2008, 02:16 PM   #19
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did a little minor trimming last night to get a little extra clearance for the down pipe. Now the down pipe is off to a guy that does welding for my dad's business so he can add a new O2 bung. He's also going to clean up the welds a little bit, and I'll probably hit it with some high temp paint to make it look a little better. Must I remind you that I'm working on a minimal budget?




I also have all the intercooler pipes finalized. I'll eventually get some of these joints welded together, but for now, the tacky blue hoses will have to do.


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Old 03-20-2008, 02:37 PM   #20
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Are you using a v-mount intercooler? I am considering one using an over-the-top method with 2" pipes like yours.
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