New level of cheap DIY....
 

This post is a bit premature, I still have a few weeks of fab work to go, but I thought I'd start it here anyway so I can organize everything in my head and see what I still need....

So the original plan was to wait until I had all the right parts piled in the garage, then go ahead with the install. Well, thanks to ThirdGen letting me drive his car at 7psi, that went out the window. So the new plan is throw some crap together, make some damn boost, then come through and redo it all slowly. I'm out of patience. So first the pricing so far.... Keep in mind the car already has MS, a LC-1 and a boost gauge....

Turbo -
Used Saab unit, .48 turbine 50 trim compressor - $25

Manifold POS DIY log style - $32 total
Manifold flange - $20
2 1/2" sch 40 pipe - $2 (Lowes scrap)
3/16" plate - $10
T3 flange 1/2" Scrap DIY - free

Wastegate -
XS Power 38mm 6psi spring - $65

Downpipe -
1/2" turbine flange - $13
2 1/2" pipe w/ mandrel bents left over from cat back
3" pipe w/ mandrel bends cut off my old Suburban

Intercooler -
Used Starion unit from forum member $30

Intercooler piping -
Scrap 2" conduit w/ lotsa pie cuts - free

Water lines -
Hard lines reused from turbo - free
Hoses from an old motor - free

BOV -
Old Bosch unit - free


More to come, still have to get oil lines, an air filter for the turbo and a set of injectors. But I'm at $165 so far and will be boosting soon.... (finally)
--Alex

:useless:

x2...post some pics ASAP of your extreme budget build.:)

Make sure to use a couple flexible couplers in the IC piping. Conduit is pretty awful for fatigue/vibration loads.

hehehe sounds fun so far :)

that's the same turbo I run... it seems to be a good fit for a stock bottom end.

what are you doing for fuel and timing?

Pics will be coming soon. The intercooler is in, I'm running the piping to the TB now. The manifold is mosly done, just need to mount the turbo flange and EWG plumbing. That should happen this weekend, but I may go bone yard hunting for injectors instead.

The intercooler piping will have a few couplers in it. I was thinking for easy removal / upgrades, but yea vibration resistance is important too.

I did forget to mention that EMT conduit is galvanized and welding it is a very bad idea w/o serious ventilation. I'm using a light industrial fan to ventilate the area and have the hose of the shop vac next to the weld as a fume scrubber.

MS will deal with all the fuel, timing, EBC, over boost issues.

Glad to see someone else running this turbo with good luck. I have a TD04B compressor sitting around too, but the backing plate was corroded and broke when I took it apart.

Forgot about the DP and BOV, I'll update the first post. Still haven't decided on 2.5" or 3" for the DP. I have the tubing for both. Real exhaust stuff even.... The cat and back is 2.5, so I'll probably stick with that for now.

This has been a blast to do so far. A lot of cutting and welding for those pie cuts though.

I've been waiting too long to get it all "right". It was time to say screw it and just build some shit.
--Alex

In for pics!!

First pic....

So there you have the beginnings of the manifold minus flanges. (Not to worry, there's a new one in the works already)

The IC pipe on the left is from the TB dropping down, the one on the right is the first 90 off the IC. I'll have better pics of that soon when I take the nose back off.

I threw in the EWG, BOV, oil line tee and home made T3 flange just for kicks....
--Alex

awesome build. That's right up my alley.

man, I'm jealous. I wish I could have done a turbo for 1/10 what I spent!

TB to IC pipe in place. In keeping with the low budget theme, I decided to use blue painters tape instead of silicone couplers....
--Alex

Hahaha... +1 on the tape.
I'll give you 50 extra ghetto style points.

For some reason I do not foresee that as a viable permanent solution :giggle:. Very ghetto though :)

Are you using MIG or stick on that manifold?

That TB pipe is actually a really nifty shape. Reminds me of the old adage- "It's not how good you can weld, it's how good you can grind." :bigtu:

Very nice!! :D

LOL I love the tape, but I doubt it will ever see any boost without vibrating off/blowing off. Very creative :)

I would have used duct tape instead of the painters tape. That way it would almost look like it was part of the TB.:rofl: