BDR

EDIT: This will end up becoming my build thread. I have one out there but since I've been using this instead...I'll just keep it all here.

Engine is a stock LQ4, rebuilt, TU2 cam, Victor JR intake. It'll be blow-thru with a CSU carb running on e85, 17# boost.

Turbo is a s475.

Car is at the body shop getting painted..backhalved 91 Camaro, full cage.


I feel kinda dumb posting since it will take a while for what I'm actually posting to do. I am going to modify my stock manifolds (I have 2, just in case I mess up, OR..if it comes out good, I'll make 2 kits and sell one) to accept V-band flanges to a T6 frame turbo. I've never REALLY welded before so I'm taking a welding class that will teach me ARC and MIG welding..it starts 1 week from Monday. A local machine shop said that they'll teach me to TIG weld...so I'll buy a TIG after I'm proficient. I have a Century MIG welder from a friend of mine which I will be using. Messy garage.. I'm reorganizing to make room for welding, a blast cabinet etc..

Pics of my Camaro before paint and headers before welding are attached.

BDR

It's gonna be a slow process. Hopefully I can get my motor/trans next week and start on the turbo placement and piping. In the meantime, bought a Hobart Handler 210MVP and modified a set of headers. I had cast manifolds and 1 had 2 cracks and a hole that I accidentally made so I fixed it. Noob welder here btw.

My truck mani's had 2 cracks in them so I fixed it, just need to blend it in. While I was using a grinder, I cut a hole in the primary while trying to clean up and remove the boss...and of course my new welder.

BDR

These are JBA headers..got them from a friend..so I added v-bands to them. I'll add some more weld, blend it in, then see how it fits on the car with the engine. I'll add vbands to the truck mani's also. Also a pic of my Camaro after painting.

Citation X

That looks really good silver.

BDR

You didn't like the primered doors and red everywhere else? Lol

Thanks! I'll take more pics as I make more progress.

CharcoalBird

iTrader: (4)

Very nice, BDR! I moved from San Antonio back in 08'. I miss it sometimes.

BDR

CharcoalBird:

Thanks! Yea its ok here..you're not missing much other than the heat and humidity.


Finished modifying the truck mani's and blending them. I'm going to add more weld to the JBA headers and blend them also that way they look better. Next week I'll install the motor/trans and actually get some real work done.

BDR

Made progress.

Installed my th400 and LQ4. I bought this BMR Th400 crossmember but my setup wouldnt allow me to go back far enough to use it. Well, the original crossmember will work. Its off by maybe a 1/4" too far forward. So I'm going to add some thick steel plate to the bottom side of the crossmember so it extends out about 1" and be done with it.

The JBA headers I modified..well..the drivers side didnt clear the steering shaft. I didnt/dont want to modify the header to "make it work". So I installed the truck mani's. The problem is that the drivers side was too close to the steering knuckle, so I modified it again and have plenty of clearance.

In one pic you'll see a yellow glove..thats the drivers side mani with very little clearance..before fixing..

I'm also running a "muscle car" oilpan. It sits a little low. Just in case anyone is interested, I'll take a pic. I'll be replacing it also.

BDR

With all the room...looks like I'll mount the T6 turbo in the front and route the manifold out to the turbo from the bottom. The exhaust will go out on the pass side.
I'm using my old parts for mockup..one thing a friend of mine thought of is mounting the alternator direct to where I had the idler pulley. Just need to add a adjustable bracket to add tension. Should work out well since it lines up perfect with the wp. I'm going to use square tubing (just 2, not 3 like in the pic..the 3rd is just to hold it up for photo purposes) to mount the turbo where it sits. I saw another TGO member do the same and will do that also.

Jay_rich

iTrader: (4)

Looks good. Similar placement to my old t6 setup. I ended up moving the rad right in behind the front bumper and angled it a bit since i used a 19" tall rad.

Mani's turned out great!

Jay

BDR

Thanks Jay... only problem is..now that I put the engine in the proper location, the passenger side hits the k-member. Now I need to modify it again. should have that done this week. I might give your radiator placement a shot also. I have a pretty big aluminum rad though.

Jay_rich

iTrader: (4)

Ya I just got done patching my k-member. On my old setup I used a pretty well stock sized rad. I think it was 31x19x3. Generic griffin. I had to angle the bottom a bit if I recall right. Been around 6 years now :s

Jay

BDR

AAhh..nvm.. I have the same radiator.. 31x19 or so..its pretty damn big. Might pirate your idea on that.


More progress today. Since I didnt have the engine in the proper location and now finally do, the passenger side manifold hit the kmember. The JBA headers need more modification to work and I'm not going to use them, so they'll be shelved for a different project.

Had to cut a notch out of the pass side mani and then modify a 2.5" piece of exhaust tubing to fit. Took me quite some time to get it where it is now. So I tack-welded it in place to see if it fits well in the car. Tomorrow I'll finish grinding some more and molding it to the mani before doing the final weld. Then I'll add a v-band flange to it. In the pic where the mani is in the exhaust tube, that is before an hr or so of grinding and fitting over and over..

If it looks like it will hit the heater out on the wp, that will actually be blocked off since I will have no heat.

BDR

Ok.. the manifolds are done. Almost symmetrical. Now I'll make the bracket for the turbo and route the tubing to the merge.

5spd-iroc

keep it up this is basically the build i wanna do eventually, gotta sell my 406 first

BDR

My 2.5" alumized tubing came in today from Summit. I need to make 2 90* bends and 2 45* bends. I can cheat and buy mandrel bends...but thats boring.

Here's the first. I'll post up when I make more progress.

BDR

Went lookin around Craigslist for a drill press and a blast cabinet. Picked up a 12" Craftsman drill press w/laser indicators, digital depth gauge etc for $90, its on Sears for $179. Then picked up a Harbor Freight 40# blast cabinet for $100...then bought some more tools from Northern :-)

Finally got some parts in.. T6 form, 2.5" --> 3" merge, mandrel bend, 1/4" steel plate.
I didnt want my turbo bracket permanently welded in place, so I measured the width of my bracket and cut out some 1/4" plate that I'll weld to the frame.

The bracket is bolted to the 1/4" plate. I need to do the final welding/cleanup for the bracket and the mounts it is bolted to along with some black paint on the mount.

Up next is the exhaust to the merge tubing.

pmcruz781

I like you build man. What made you go with the s475. I like it, I have seen them make some big power on mustangs.

BDR

Thanks.

I bought it new for a cheap price. Looking back a s480 would have been better for more power. I'll go with 20# boost initially and then I'll start on a forged bottom end LQ4 with ported heads and may change the turbo out to the s480 depending on how much hp the current setup makes.

BDR

More progress.

pmcruz781

Looks like you getting there, I am looking to do almost the same setup on my car. I can't wait to see how it turns out.

BDR

Thanks. I'm going to clean up the manifolds this weekend and then order my carb hat. I'll start on the cold side next.

LilJayV10

iTrader: (5)

Very nice work. This has convinced me to use truck mani's except I think I am going to do two small twins. I'll be watching this thread!

LilJayV10

iTrader: (5)

What sch pipe did you use to weld onto the manifolds? If you said I missed it.

BDR

16 gauge alumized steel.

BDR

I need to mount the radiator somewhere a little further north that way I can have room for the dual Derale fan setup. I made some L brackets and welded it to the metal that supports the front end. The bracket sits about flush with the front lip. Right now the car sits a little high, maybe with a full trans (its gutted right now) and whatever small parts I have, it’ll lower it a little. If not, I’ll replace the Moroso drag springs with some that lower the car and I’ll counteract that with 27″ tall tires. Just need to fill up the wheel well in the front since it looks like a 4×4.

Another “minor note”…I picked up a very nice Harbor Freight Plasma cutter. COULDN’T BE HAPPIER! Sells for $699..bought it brand new for $400 off of Craigslist. I used it to cut out the old core support and radiator brackets.

On the exaust coming out the turbo, I’m initially going to dump it by the passenger fender. After I tune it and get it ready for the street, it’ll have a full exhaust.

NemeSS-TyranT

iTrader: (1)

Turbonetics sells a pretty cheap carb hat. If ur looking to save a few bux over an extreme velocity one.

NemeSS-TyranT

iTrader: (1)

The 4in spectre carb hat works as well. Prolly better than the tnetics and a lil cheaper

BDR

I'm going to run CSU's hat since I've used one on my previous setup.

LS1BADZ28

You should mass produce that hotside and turbo support....

BDR

My welding and fabrication skills are nowhere near as good as some stuff I've seen. Its not good enough for someone else's Camaro. After I finish my car, I will attempt to make another but if it looks like shi*, I wont bother selling it. Thanks for the compliment though.

LS1BADZ28

I think cutting the brace off after the passenger side of the turbo would work, do you? Can you fit a 4'' pipe down and to the fender? I think the setup looks great...I seriously would buy the hotside...PM me

LS1BADZ28

Also, do you plan on running dual wastegates?

BDR

You mean only have 1 square tube holding up the turbo on that side? If so, then no. This turbo is very heavy.

There are things that I didnt do right that I know now. For example, I put square tubing across where the radiator support is. Well that gave me clearance to where I could have moved the turbo to the middle and moved it farther up closer where the radiator used to sit. That would let me run the 5" exhaust (temporarily for me) right where the battery goes (its relocated to the back) and the cold side on the other side. So as it sits now, I'm still going to run the exhaust thru the battery tray except I need to turn it at a 45* angle right before the fenderwell and then the 90* drop thru the battery tray. I'll do the same on the cold side also. Then with the turbo in the middle, its a straight shot to the carb if not using an IC. As it is now, since I will run an IC, its fine the way it is but moved up more would have made the cold side and exhaust have 1 less bend.

I'm relocating the radiator and then installing an intercooler in front.

No, just a single WG.

LS1BADZ28

I meant the bars coming from the driver side frame rail, to the turbo, going completely around the turbo flange and ending. My buddy's 4th gen S480 support was basically a 1''x1'' bar going from the frame rail to the flange, welded to an L that bolted to 3 of the flange bolts. It's held up great.

LS1BADZ28

Cutting off at the X's

BDR

aaah ok.. yea i'm a paranoid guy. I dont want my turbo falling through. LOL

BDR

Dropped off the manifolds to get thermal coated. While thats going on...

I decided to grind off some welds and do the final weld on the hot side, clean up the inside so it doesnt have any excess crap in it. While I was welding (started on the pass side, bottom left), the welds didnt look all that great. I'm a noob welder, so on this thin stuff I did not so great until I talked to Jay_Rich. Got a few tips and applied on the drivers side (to the right of the pass side tube) and it started coming out much better. Unfortunately for me, I learned this after I finished the passenger side. So I'm basically grinding a little off and making it look smooth. Since I have off tomorrow also, I'll look to finishing this tomorrow and then the welding it all up when my manifolds come in.

Jay_rich

iTrader: (4)

Looking good man, glad my tips helped!

Jay

BDR

Got my manifolds back. Thermal coated inside and out. The rest of the hotside, I deburred/smoothed out the inside and out. I'll weld the last 2 exhaust tubes on and smooth out if needed, then drop it off to get coated. Also pictured is the 31x12x4 intercooler I bought from CXRacing.

BDR

Intercooler mounted. Now the waiting game... once the coated hotside gets in, I'll do the plumbing for the turbo --> IC --> carb.

406TPI

iTrader: (1)

Your manifolds turned out nice. Good job.

BDR

Thanks!!

3rdgencamaros

Make this two of us-

BDR

Ok. Added wg. I'll shorten the tube and drop it off to get coated.

http://imgur.com/XCHEGkC
http://imgur.com/M4K6zda
http://imgur.com/s4qUgi5
http://imgur.com/lzpy8Lj

Jay_rich

iTrader: (4)

Looking good! Looks like it will flow in nice. I assume you know you missed a weld on the crossover pipe? I noticed it as soon as I opened the 3rd pic lol.

Jay

BDR

If you're talking about the part where the t6 flange meets the merge pipe, I saw it but didn't think it needed to be welded. Meaning, if it falls apart there, I'd be surprised. For consistency, should I have welded it..yea.

Jay_rich

iTrader: (4)

Copied the pic lol. Id hate for you to send it for coating and find a leak!

Jay

BDR

Oh crap. No I didn't see it. I'll call them when they open. Thanks!!!!

cheesehomer

iTrader: (2)

I agree, Great job ....subscribed ,,Gotta see how this turns out.