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Old 11-29-2007, 05:31 PM   #1
dunk
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Default Reverse Intake Manifold Project

Well,

My project for this winter is to reverse the intake manifold on my car. I'll update this thread as I make progress on the project, should take about 3 weeks to complete.

I started by removing the charge pipes, intake manifold, alternator, and turbo.



Knowing that I wanted to significantly reduce the length of the intercooler piping, I decided to reverse its direction. The easiest way to do this seemed to be to clock the green so the compressor outlet faced the passenger side strut tower. This required grinding off all the bosses for the IWG. Not a problem, since my car has a TIAL 38.





Here's a picture of the turbo mounted in the car. I should be able to use the 90 degree coupling from the old piping.



On the intake manifold, it was necessary to grind off the boss on the bottom used to secure the main engine wiring harness. This allows the intake pipe to fit in the same location.



Today I built the brackets to secure the alternator in it's new position, and welded up the extra bung on the coolant header tank I'm not using because my green is an oil cooled only turbo.

More to follow

Duncan
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Old 11-29-2007, 07:00 PM   #2
japslapr
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wow. Great idea. I already have the rotated manifold but didn't think about the piping bend from the turbo. It is kind of a nasty bend that has to be made. Look forward to seeing how it turns out.
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Old 11-29-2007, 07:22 PM   #3
SirWilliam
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Sounds good. Hope everything works out for you. Keep us posted w/ pics
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Old 11-29-2007, 08:55 PM   #4
soundslikeboxer
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just saw this car in person yesterday. it looks NASTY!
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Old 11-29-2007, 09:22 PM   #5
pjhe
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dunk,

fire an email over to scott (at) usrallyteam (dot) com and tell him i sent you and what you're working on...

he may have a goodie he'd like you to try on for size
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Old 11-29-2007, 11:47 PM   #6
subyrally
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cool beans, looks like its going to be fun.
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Old 11-30-2007, 06:38 AM   #7
dunk
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Quote:
Originally Posted by pjhe View Post
dunk,

fire an email over to scott (at) usrallyteam (dot) com and tell him i sent you and what you're working on...

he may have a goodie he'd like you to try on for size
thanks, sent him an email.

Duncan
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Old 11-30-2007, 09:14 AM   #8
SilverBoosted
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ummm why would someone want to do this??
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Old 11-30-2007, 09:23 AM   #9
agterlik
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Quote:
Originally Posted by SilverBoosted View Post
ummm why would someone want to do this??
Are you seriously asking this?
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Old 11-30-2007, 09:39 AM   #10
Capt Crunch
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Quote:
Originally Posted by dunk View Post
Knowing that I wanted to significantly reduce the length of the intercooler piping, I decided to reverse its direction. The easiest way to do this seemed to be to clock the green so the compressor outlet faced the passenger side strut tower. This required grinding off all the bosses for the IWG. Not a problem, since my car has a TIAL 38.

Duncan
Yay! I have had this idea for years and pitched it to several vendors. None of them thought it was a good idea. I've been waiting for someone to do it!
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Old 11-30-2007, 07:22 PM   #11
dunk
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Default

Made a little more progress today, here's some new pictures.

This is from mock up of the intercooler pipes. Nice short run for the hot pipe. Nothing is welded yet, just set in place until I'm sure it's where I want it.



Good pictures of the beginning of the cold side plumbing, as well as a front shot of the belt. You can see the timing belt idler pulley (thanks Vern). Just had to drill and tap the hole on the alternator bracket to the 10x1.25 size for the pulley. You can also see the bracket that holds up the alternator in this picture.



Close up picture of the throttle body. You can see I've removed the cruise control arm.



This is the coolant header tank top. As I have an oil cooled turbo, I decided to remove the nipple for the coolant line and weld it up. That way I don't have to worry about a hose cap rupturing at the track.



Checking to make sure the intake still fits.



Trying out some possible locations for the BOV. Top of that intercooler pipe will be cut off and rotated to face the center of the car.



I'm hoping to finish up the intercooler piping this weekend, that way I can start breaking everything down and getting it prepped for paint.

thanks

Duncan
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Old 11-30-2007, 09:17 PM   #12
THE-95-STi
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Why don't you just elimnate the Resivour completly, seems pointless to keep it

all you have to is get a longer silicone hose(from autozone) and re-route to where its going in the first place

you can see how I did mine in this pic
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Old 11-30-2007, 09:28 PM   #13
dunk
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I would, but I'd need to have a filler neck put on my radiator.

Duncan
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Old 11-30-2007, 09:40 PM   #14
5spdfrk
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I look forward to seeing the outcome.
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Old 11-30-2007, 10:28 PM   #15
pjhe
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Quote:
Originally Posted by Capt Crunch View Post
Yay! I have had this idea for years and pitched it to several vendors. None of them thought it was a good idea. I've been waiting for someone to do it!
i've got that covered
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Old 12-01-2007, 12:39 AM   #16
StillBoostin
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Just get a STi Radiator.

James
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Old 12-01-2007, 10:02 AM   #17
dunk
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Default

Quote:
Originally Posted by StillBoostin View Post
Just get a STi Radiator.

James
Don't want to spend the money to get another aluminum radiator. If I wanted to delete the header tank, it would be cheaper to have a radiator cap welded to the radiator I already have.

Duncan
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Old 12-01-2007, 11:03 AM   #18
THE-95-STi
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I have one, sell it cheap
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Old 12-01-2007, 11:26 PM   #19
Unabomber
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Looks great so far buddy! We actually have decent intraweb speeds for now so I can see this. I'm sure you've thought of this, but not would be a great time for that APS inlet. Also, some Grimmspeed phenolic gaskets. I can get you a deal on the gaskets, but no deals are to be had on APS stuff.
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Old 12-02-2007, 10:34 AM   #20
Capt Crunch
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Quote:
Originally Posted by Unabomber View Post
Also, some Grimmspeed phenolic gaskets.
Aren't they supposed to be the debbil now?
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Old 12-02-2007, 05:19 PM   #21
Unabomber
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Not debbil now that I know of. You mean the gaskets themselves or Grimmspeed? Both are fine still as far as I know unless something has changed within the last 3 months as my world's slowest internet has kept me off the forums.
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Old 12-02-2007, 05:49 PM   #22
dunk
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Well, made some more progress over the weekend. Got all the pipes cut and welded up, thanks to a friends neighbor, Javier, who is a Navy Hull Technician. Also big thanks to All Aspects Motorsports for lending me the TIG welder. Now onto the pictures.

Picture of the hot side tubing. I decided to place the BOV here for ease of packaging.



Front pipe all tack welded up.



Another shot of the same, different angle.



Tack weld on the charge pipe.



After tacking everything in place it was carefully removed from the car, and welded on the bench. Here's some pictures of the completed pieces off the car.







Finally, everything was reinstalled in the car to check for fitment.







I've also decided to remove the coolant header tank from the system. I'll purchase a weld on filler neck and transfer it to the radiator. Next I'll start tearing everything down from mock up and prepping it for paint.

Duncan
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Old 12-02-2007, 08:41 PM   #23
Capt Crunch
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Quote:
Originally Posted by Unabomber View Post
Not debbil now that I know of. You mean the gaskets themselves or Grimmspeed? Both are fine still as far as I know unless something has changed within the last 3 months as my world's slowest internet has kept me off the forums.
Never mind, I was thinking of Gimmick Motorsports... they were supposedly caught copying Kartboys SS.

Dunk, your setup looks really clean, it's gonna be the best bolt-on engine bay ever.
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Old 12-02-2007, 08:46 PM   #24
wrxracer519
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the manifold looks great, keep up with the great pics
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Old 12-02-2007, 09:12 PM   #25
RaceFaceXC
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Who makes that intake manifold? Is it a STi manifold? If not, do they make one for the non-turbo engines? more specifically a '07 2.5i??? Nice setup, looks like you cut out some bull**** and cleaned it up well. Hope it turns out great. can't wait to see the finished project.
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