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Old 05-08-2012, 07:03 PM   #1
bmw325ix
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Default GR STI V-Mount, Rotated TO4

Almost a year ago I built myself a rotated factory turbo setup with a front mount and a reversed intake manifold. Now the time has come that the original clutch has given into the power. So natural its time to build it bigger, up and down down pipe to accommodate the T3/T04E 60 trim turbo. New 3 inch exhaust and most of all a slick V-Mount intercooler/radiator. Today was the first day of mock up for the front end, materials are on order for the exhaust side of things so untill then its the front end. Sorry for the cell phone pics but I want to stop and take legit pics.

First the factory upper and lower radiator supports got sent to the scrap bin,




I mocked in the radiator next, it looks massive laying like that but its actually shorter then a mishimoto aluminum replacement. What you see is a generic AL radiator from JEGS that will get some massaging later,




Now both the intercooler and radiator, the hood will close all the way when i pull out the silly rubber seal around the hood latch.



Tomorrow I am going to a buddies shop who has a pipe bender to make the new radiator support and crash beam

And a pic from when I pulled the factory turbo and just sat the new turbo in there

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Last edited by bmw325ix; 05-08-2012 at 07:11 PM.
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Old 05-08-2012, 09:54 PM   #2
2006whitesti
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Looks good so far. Will check back for update. Bravo for doing your own work and doing something different.
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Old 05-12-2012, 08:44 PM   #3
Thomas Ruble
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Looks great man. Your very skilled.

Not to take anything away from your excellent work. You might want to consider fabricating a duct for the radiator. I have a Process West V-mount (the first unit in the U.S.). I a fabbed up a carbon fiber duct which seems to work well. Eventhough the Process West radiator uses a "stepped core", I decided to make it more efficient which is why I added the duct. I didn't like the idea of air escaping around the sides of the core. With your skill you could easily weld up aluminum plates onto the sides of the end tanks, or possibly weld plates onto the radiator support or crash beam.

Keep up the great work.
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Old 05-13-2012, 04:10 PM   #4
bmw325ix
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Thanks for the compliments, I havent had time to upload here this week.

Here is the new crash beam/ radiator support. Its made of 1.5" DOM tubing, and I'm confident it weights less then the factory beam. Living in new england this car is my winter car so it will be seeing snow bank contact. You can also see how that radiator fits with the factory frame work cut out.



As you would think there was a lot of bumper trimming required to fit the bumper cover but its all worth it. They are all rough cuts for not and when its gets closer to finishing time I will clean up the edges.




Now I'm waiting for materials to come in for the new ewg up pipe and down pipe combo. Also aluminum tubing is on its way for the new coolant pipes.

Last edited by bmw325ix; 06-14-2012 at 08:28 PM.
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Old 05-13-2012, 04:13 PM   #5
bmw325ix
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Quote:
Originally Posted by Thomas Ruble View Post
Looks great man. Your very skilled.

Not to take anything away from your excellent work. You might want to consider fabricating a duct for the radiator. I have a Process West V-mount (the first unit in the U.S.). I a fabbed up a carbon fiber duct which seems to work well. Eventhough the Process West radiator uses a "stepped core", I decided to make it more efficient which is why I added the duct. I didn't like the idea of air escaping around the sides of the core. With your skill you could easily weld up aluminum plates onto the sides of the end tanks, or possibly weld plates onto the radiator support or crash beam.

Keep up the great work.

Duct work is certainly in the cards but that's something that will wait till its up and running. I really want to run a Impreza scoopless hood and cut an exit vent in the hood similar to what the evo 8/9 have.
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Old 05-18-2012, 09:32 PM   #6
bmw325ix
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Updates,

Up pipe tacked up, not terribly interesting. The ewg will be added later.



Turbo sitting in place,



Purge welding the DP, I have only made it to the point were it passing the fire wall. tomorrow it goes up on the lift to make the rest.

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Old 05-18-2012, 09:35 PM   #7
bmw325ix
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This is how it looks welded up,



I'll be that guy, here is a weld



In the car, its tight to the tranny because the ewg takes up its fair share of space on the other side.






Last edited by bmw325ix; 05-18-2012 at 09:55 PM.
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Old 05-22-2012, 03:16 AM   #8
B.R.E.D
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Nice work, I really like the Vmount setup.
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Old 05-22-2012, 08:13 PM   #9
25rsti
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Looking great so far! Keep up the awesome job.
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Old 05-22-2012, 10:30 PM   #10
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gonna be doing this set up very soon. What ic and rad did you buy if you dont mind me asking??
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Old 05-22-2012, 11:32 PM   #11
bmw325ix
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The rad is a generic something off jegs, I actually bought it years ago for my v8 e30 race car project but it just so happened to fit for this. I'm going to have to modify the inlet and outlets but for the price I don't mind. The intercooler is something cheap off eBay, I figure I'm going to cut it up anyway and I don't have the tooling yet to make my own end tanks, at least not to my liking. My fab tools are pretty standard right now, mig, tig, drill press, and a small table. I'm looking into 3 in 1 sheet metal machines and a band saw soon.
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Old 05-23-2012, 12:13 AM   #12
bmw325ix
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By the way I bought the intercooler from just-intercoolers on eBay and it's pretty obvious that it had a hole in the core at one point and it was repaired. I have contacted them about the issue and all I got was an offer to refund me the $10 they think will cover having someone weld it again. I don't know if it leaks but I'm not happy.
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Old 05-23-2012, 01:51 AM   #13
808-wrx
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Im thinking of running a style like this
Amazon.com: Front Mount or V-Mount Turbo Intercooler 25"x16"x4": AutomotiveAmazon.com: Front Mount or V-Mount Turbo Intercooler 25"x16"x4": Automotive

Lay it flat with the core support so the ic piping is super short. tilt the rad all the up. I was also gonna make some type of diverter for some fresh air to get the turbo inlet. Hopefully soon i can get rolling on the project. Waiting on the funds to buy the tig welder haha sucks.
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Old 05-23-2012, 11:21 PM   #14
bmw325ix
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I finished the hot side of my new setup




Last edited by bmw325ix; 05-23-2012 at 11:57 PM.
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Old 05-23-2012, 11:40 PM   #15
fourmicah
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Very cool build!
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Old 05-24-2012, 01:12 AM   #16
Surb00
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Cool setup! Props for having the guts to cut up a GR. Watch the heat/travel speed on those welds. Any weld on stainless that turns gray can and will rust.
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Old 05-24-2012, 08:40 AM   #17
bmw325ix
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I know i need to pick up the pace with my welds, I don't know if im going nuts but the welds seemed to gray more over time after I was done. I let the back purge keep going while everything was cooling but maybe its just me
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Old 05-25-2012, 08:28 AM   #18
25rsti
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Hey, I'm gonna try and stop by today.
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Old 05-25-2012, 01:04 PM   #19
Surb00
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If the material is still too hot it will change color after you remove the torch. There's no one solution its got to be a perfect storm of travel speed, amps, torch angle, tungsten stickout, gas flow, and torch setup. If you have any questions I'd like to help. I am a fabricator and TIG 304 everyday. What model of T3/T4 is it?
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Old 05-26-2012, 09:33 AM   #20
bmw325ix
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T04E 60 trim, stage 3 wheel, .63 housing

I'm kinda at the point with welding 304 that I can tell when I'm not really doing it just right, so now its just figuring out how to make better. I'm thinking of getting a bigger cup, I already use a gas lens but since there isn't much space constraints on an exhaust why not. That being said I believe my welds right now are plenty strong but there is always room for improvement.
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Old 05-28-2012, 03:22 PM   #21
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Try using a slight backhand or dragging angle on the torch. It puts more gas on the hot side of the weld rather than blowing it out the front on cold metal. Im interested in dyno results. I've been tempted to ditch my GT series and go to a 50 trim T3/T04E.
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Old 05-28-2012, 09:02 PM   #22
bmw325ix
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I'm aiming for 500hp, thats at the crank. As of now the internals are stock but I will run them for a bit, gets the bugs out of everything and then upgrade the internals. I have a short block to build so I can just swap it in. This is my daily driver usually so I don't want to go to crazy with boost
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Old 05-29-2012, 10:42 PM   #23
bmw325ix
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I made the rest of the exhaust today, silly GR needs so many bends to clear the rear subframe and then make a muffler work in the back. I tried to photo graph it but for some reason it just looks flat in pics so I have to try again later.

I made it out of 3inch 304SS with a vibrant quiet resonator and vibrant black muffler, no fancy tip just a pipe out the back, the way I like it. I also used 2 v-band clamps to hold it together, I like to make exhausts have sections so it easier to take them in and out.

Last edited by bmw325ix; 05-29-2012 at 10:53 PM.
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Old 06-11-2012, 02:25 AM   #24
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Awesome stuff!
Is your motor in the stock position? It looks to be pushed back a bit.

I have a "pipe dream" (sorry) of craming a PW v2 VMIC into my GR.
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Old 06-12-2012, 11:18 PM   #25
bmw325ix
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Quote:
Originally Posted by RoidRage
Awesome stuff!
Is your motor in the stock position? It looks to be pushed back a bit.

I have a "pipe dream" (sorry) of craming a PW v2 VMIC into my GR.
Motor is in the stock location
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