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10-26-2011, 07:39 PM | #1 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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New take on a practical front mount and rotated turbo
TIG welding has always been something I wanted to learn so I sold my motorcycle and bought myself a TIG. After welding together all the scrap I had I decided I needed an actual project to learn more. Enter my 2008 STI fresh back from a lengthy stay at the body shop after being smacked up on I-93.
Im building this car to fit my needs and those needs are something that's fast but I can still rip it in the snow with out worrying about a vulnerable classic style front mount. I also want a external wastegate since they are cool. So first off I built and up pipe with a fitting for a Tial MVR and since I was making my own I figured I'd rotate the factory turbo for a straighter intake path. I work as a mechanic and my boss is nice enough to let me keep this in the shop for when I can take a minute to work on it so sometimes progress can be slow. Here is the 3" DP I made out of stainless, the flange was supplied by Aaron Weir. At the end is a 3" V band flange. For an exhaust I built it out of 2.5" SS pipe for a different take on the subi sound, little more rasp. The muffler is a lightweight from Burns. The tip is a 3" turn down The intake is a 3" pipe that was my first swing at aluminum welding which was a bit of a learning curve When I put the top mount back on I was happy with it but it just wasn't as unique of a project as I had wanted So the next phase of the build happened
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Last edited by bmw325ix; 10-26-2011 at 08:03 PM. |
10-26-2011, 07:40 PM | #2 |
Scooby Newbie
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Join Date: Mar 2009
Location: newburyport, ma
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Ive always been a fan of reversed intakes, so
I want to have a front mount that retains the factory crash beam as I use it every winter verse snow banks To make it work with the shortest possibles pipes, another reason I dont like classic fmic's I bought a generic aluminum radiator from Jegs that is sized to allow the charge pipes to reach around the sides to the intercooler. The intercooler is a universal one of ebay, they are cheap and come in a million sizes, and if I do stab a hole in it its not a huge problem. To make it work I had to weld on pipes to turn the inlet and outlet the direction I needed. Yes the core isnt as big as others but it fits what I want and is still bigger then even the 08 top mount, I believe its 22x8x3.5 here you can see how the intercooler extends past the rad Last edited by bmw325ix; 10-26-2011 at 08:15 PM. |
10-26-2011, 07:51 PM | #3 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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The charge pipes was a fun bit of learning as I wanted them to be as short and straight as possible but still clear the hood and everything else that gets in the way. Yes they are made of stainless but my AL welding just isnt up to par yet so until then, 304 will do the job just fine.
The hood clears everything just fine, I did remove a little material just for the extra clearance over the throttle body area. Last edited by bmw325ix; 10-26-2011 at 08:19 PM. |
10-26-2011, 07:52 PM | #4 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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delete
Last edited by bmw325ix; 10-26-2011 at 08:08 PM. |
10-26-2011, 08:00 PM | #5 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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Some of the side elements of the build have been,
New strut brace to hold the catch can, coolant pressure tank, and coolant expansion tank I like having the pressure tank as it makes bleeding the system nice and easy. catch can, that actually just empties into the exhaust through a valve. Sweet and simple belt tensioner and a shifter extension Also changed but no photo worthy are the tumblers didn't survive and the fuel rails are now being feed in parallel by a Walbro 255. The AC is gone along with the secondary air system. Until tomorrow this is what it looks like |
10-26-2011, 08:11 PM | #6 |
Scooby Specialist
Member#: 144751
Join Date: Mar 2007
Chapter/Region:
MWSOC
Location: Granger, IN
Vehicle:02 WRX BW EFR E85 7064 TS WRB |
good stuff. I like the smaller radiator idea for the front mount plumbing. I was thinking about do the very same think when its time for me to fab up my rotated setup....
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10-26-2011, 08:12 PM | #7 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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the radiator is narrower but has a much thicker core so I'll be surprised if cooling is compromised.
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10-27-2011, 08:25 AM | #8 |
Scooby Newbie
Member#: 177913
Join Date: Apr 2008
Chapter/Region:
South East
Location: Weston, FL
Vehicle:2018 WRX STi WRB |
nice work man, what type of TIG are you using?
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10-27-2011, 08:29 AM | #9 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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Miller Diversion 165, only thing I changed was a friend gave me a gas lens for the torch.
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10-27-2011, 12:37 PM | #10 |
Former Vendor
Member#: 25194
Join Date: Sep 2002
Chapter/Region:
RMIC
Location: Boulder, CO
Vehicle:2008 Forester XT 5mt Dark Gray |
Great project!
From a fellow TIG welder (not a great one), you did a great job with the up close aluminum shots (MAF Flange especially). It is hard to find the happy medium between melting a hole through the pipe and puddling the filler. If you do plan to run the car with the MAF meter then I would suggest moving it further from the turbo inlet with at least one curve between it and the turbo. This will cut down on poor idle issues. When the sensor is directly in front of the turbo the air will travel forwards and backwards over the sensor at low RPMs, which will be a tuning nightmare. Also, I can't tell from the photo, but you may have enough room to run the 2.0 or 2.5" charge pipe under the intake manifold. This may create a few more subtle bends, but the end result will add a bit more attention to the intake manifold. This would be key especially if you opt to paint, polish, or coat the intake manifold. Just a thought, regardless your build looks great. |
10-27-2011, 03:02 PM | #11 | |
Scooby Newbie
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Join Date: Mar 2009
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Quote:
I know the MAF is a bit of a compromise, thats as fas away as I can make it. The intake doesnt go real deep into the bumper like some others so the filter mounts right after the bend. My friend who will be tuning the car was present when I picked the location and we agreed thats the best place it could be with the way the intake pipe it shaped. Running the pipe under the manifold was my first plan but it was so tight and was a real issue with the crank case breather so I just went over the top, I think it looks cool anyway. thanks for the input |
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10-27-2011, 03:07 PM | #12 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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As an update for today, I found out the steal fitting I ordered for the radiator cap on the pressure tank was actually made of crap metal and couldnt be welded with out warping into a ball. So I ordered material to make an aluminum tank.
Also moved the expansion tank back to a more stock like location. Ordered material to make the block off plate for the hood scoop that I will run in the winter to keep the snow out. When you look in the scoop now the electrical connector for the throttle is square in the middle so that probably wouldnt like getting soaked |
10-28-2011, 04:00 AM | #13 |
Scooby Guru
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Join Date: Jun 2006
Chapter/Region:
VIC
Vehicle:98' Stagea 260RS Autech Ver. |
Man! nice project! this is very similar to the setup on my GF wagon. I have a built 2.5 with a GT3076. the turbo setup was purchased used and i was running it through a tmic. got bored of it and i didnt like the commercially available FMIC setups and their massive and long piping. in the mean time i bought a diversion 180 to finish the install on the rotated kit. like you, i built an intake and some other parts.
mine will also be reverse mani, relocated alternator. similar FMIC design but with a standard sized WRX mishimoto rad. although it was a PITA to fit IC piping beside it. Its taking forever to complete because the cars my daily driver so i basically have to take it all apart, do some fab, put it back together, then repeat. Nice build and keep up the good work! |
10-28-2011, 03:26 PM | #14 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
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Today I have found out that my simple tensioner works like crap and isnt as strong as I would like it to be. So for kicks and giggles I flipped the alternator back over to the stock location and my charge pipe just so happens to clear over the top just so that settles that. The alternator is going back to the stock location and I have placed an order with grimmspeed for 8mm spacers to hopefully give the room I need for the belt tension to be set. I have the alt. pushed all the way down and it looks like a 5pk863 belt will do the trick.
Also done today, painted up the charge pipes, wired in the electric fan to the factory main fan harness, and mounted up my snow tires. Waiting for the spacers to come is going to hold me up as anything I do know is just going to be in the way for the manifold to come out. |
10-28-2011, 03:58 PM | #15 |
Scooby Newbie
Member#: 270910
Join Date: Jan 2011
Chapter/Region:
South East
Location: Saraland, Al
Vehicle:2006 WRX Tr WRB |
Wow, man. That's some really nice work there. I have all sorts of light bulbs popping on in my head right now. I.E. what can I sell to buy a TIG machine...
Keep up the good work and keep us updated. |
10-28-2011, 05:16 PM | #16 | |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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Quote:
Awesome, I know Im always more impressed when someone builds a sweet car rather then buy one. And I have confirmation on the belt size for running the alt at its lowest position. 5PK 863 is the size and in other terms its the belt for a 2002 4cyl Tacoma. Its diffinetly tight going on and you need to rotate the crank pulley to get it around and on. |
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10-31-2011, 11:15 AM | #17 |
Scooby Newbie
Member#: 258525
Join Date: Sep 2010
Chapter/Region:
Tri-State
Location: Poughkeepsie NY
Vehicle:2004 STi-BW7670 R6-Red/White |
What kind of shop do you work at with a the lambo sitting in the background? I love this build, very impressive. Drives me full of envy, not only of the car, but your skills and ambition.
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10-31-2011, 11:20 AM | #18 | |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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Quote:
Thanks for the compliment, I work at the European Garage in Newburyport MA we work on all types of high end cars. Lamborghini is our specialty. |
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10-31-2011, 11:35 AM | #19 |
Scooby Newbie
Member#: 258525
Join Date: Sep 2010
Chapter/Region:
Tri-State
Location: Poughkeepsie NY
Vehicle:2004 STi-BW7670 R6-Red/White |
Wow, my envy keeps growing. If you don't mind, Where/Did you go to school for this? How do you manage to get in there?
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10-31-2011, 02:30 PM | #20 | |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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Quote:
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10-31-2011, 04:41 PM | #21 |
Scooby Specialist
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Join Date: Aug 2010
Chapter/Region:
SCIC
Location: Lake Elsinore
Vehicle:2006 Subaru WRX WRB omgwtfbbq |
beautiful job
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11-02-2011, 05:26 PM | #22 |
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Location: Georgia
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Very nice work ... How long have you been welding to date?
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11-02-2011, 05:49 PM | #23 |
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NESIC
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Good stuff.
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11-02-2011, 06:14 PM | #24 | |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
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Quote:
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11-02-2011, 06:20 PM | #25 |
Scooby Newbie
Member#: 204652
Join Date: Mar 2009
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As for updates to the project, I spent today doing little stupid things like running all the nessecary vacuum hose ands wires, put the front bumper back on, and installed the hood pins. The factory hood latch won't fit with my front mount up so high but I would rather have the intercooler in that prime air flow spot so I made the call for pins. I was a little worried about drilling the holes but it really wasn't bad at all. I used basic sparco hood pins that my friend uses on his rally car so they seem ok. Maybe someday I will upgrade to aero catch flush mounts but until then these will work.
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