TwinTurboROC

>>>>>>Since a few people were asking, I'm re upping all the PICS. THIS IS A OLD BUILD. CAR WAS WRECKED<<<<<<
>>>>>>Since a few people were asking, I'm re upping all the PICS. THIS IS A OLD BUILD. CAR WAS WRECKED<<<<<<
>>>>>>Since a few people were asking, I'm re upping all the PICS. THIS IS A OLD BUILD. CAR WAS WRECKED<<<<<<

So finally got motivated to finish this rat trap. Here we go. More pics to follow as i get time. Enjoy

Specs
Going on the 305 TPI in my blue pos.



Random T76 Turbo - re-branded china one with a improved compressor back plate. .80 compressor/.81 turbine





Knockoff Tial 46mm Wastegate




Being sent back, Going with the V band mount instead that should have been sent.
Installing a Genuine Tial diaphram after it gets home.

255 lph walbro already installed.

Cold side TBD

1 5/8
2 1/2





4 inch straight and a 2 1/2 straight





From a 4 foot section of 1 5/8 made some chibi collectors. Hope you guys like my wood jig. LOL

TwinTurboROC

More Cheese and Beef



After the angled cuts




Coming Together




After welding



After smoothing with a file.



And a little 4 inch 180 for exhaust.

TheRock86

cant wait to see the progress on it

Street Lethal

iTrader: (16)

Hmm, I like where this is going...

project89

iTrader: (1)

nice job on the collectors

just curious would u be willing to sell me 8 or 16 pieces with the cuts on them

SKELITOR117

iTrader: (3)

Sweet. Nuf said.

Orr89RocZ

iTrader: (20)

Very nice on the collectors. I didnt have the patience to try and make something like that. Not sure I even could do that.

TwinTurboROC

Dave ill see what i can do. I am outa piping atm, and right now im uber busy, but not getting much accomplished. Im finish up the collectors today/tonight and post up some pics later. Was hoping to pull the car apart this weekend and get started on the manifolds but to many car meets this weekend. And with car meets come hot women. So f the car.

Btw, what are your thoughts on studding the head? And yes this motor is staying stock, staying TPI style. I can't wait to spit a rod out the side of the block.

Also, anyone running the new walbro 3950 400lph pump? (pic below) Im waiting to see if i should use that and my current 255 together but the 400 has a Gigantic bottom, and im worried about it not fitting in the tank opening with the 255.

project89

iTrader: (1)

wow i didnt even relize they made a pump that big yet, i ende dup going with 2 aremotive stealth 340lph pumps

using that walboro with the 255 prolly wont fit int he tank , its hard enough squeezing 2 normal sized pumps in there

head studs wouldnt hurt but they make it a pain int he *** to get the heads on and off in the car if u ever need to replace a head gasket .

if its a stock motor i wouldnt even bother with studs id just go an aditional 5-10FTlbs on the stock bolts

Drac0nic

That 400 is frickin HOT. Can't wait to see how it stacks up to the 340s. Can't wait to see what this build does either. A 76 on a 305 is a ton of head unit, should be able to really lean on that engine and see what it can do!

I hope you're dealing with the "Decent" TPI cam or planning on bumping up. Even with the peanut cam I'd be curious to see how you handled that snail. May surprise me but I'd think it'd be sluggish without some more cam.

TwinTurboROC

With the pump im may mock up something to spring load the pump so i can install it and the float at the same time, or vice versa and swing arm the 255lph and use the 3950 on the main fuel sender frame. I cross that bridge when it comes.

As far as the turbo, it "should" spool fast. I went with a smaller housing (.81) so I can take advantage of the TPI system low end. I will probably need to run a LTR or siam runner setup. Thoughts of new valve springs/hydra rev kit are floating around my head. But after a bit of time im gonna push that poor lil 305 to its limits. Honestly i wanna get this thing together so i can do a ground up on my black iroc-z. More pics tomorrow. To tired now to function.

Street Lethal

iTrader: (16)

... a little overkill for a stock 305-TPI.

TwinTurboROC

Overkill... hmm ill check the dictionary for a definition.

Street Lethal

iTrader: (16)

You could pull the electric pumps and throw a mechanical pump on that 305, and with the way these stock TPI's breath it'd still be too much fuel for it to handle...

TwinTurboROC

Yeah its ghastly how they are untill you go at them w some porting tools. And even then its just still sad. Until you boost them. Dont look like im gonna get much accomplished today. Top gear UK all day. I got to stop being lazy.

TwinTurboROC

Collectors finished up. The transitions were grounded down a bit.

peterc005

Subscribed

vortec350s10

Those collectors are sweet! Nice job. For the pump setup, I would agree that a 400lph is definitely overkill. But hey, better than not enough. Why add to the 255 you already have when you could just run a 340 or 400 by itself? I have a stealth 340 and it fit and works great for me so far. Can't wait to see the hot side progress.

Drac0nic

if I had a 400 like that and a set of injs that were big enough to do it I'd skip right to E85. No use playing around in gasoline land.

TwinTurboROC

Draconic, I would do e85, but i hate that you got to go to specific gas stations to get it. Long Island sucks like that. And as of now this is a drive it everywhere car.

Vortec350, I plan on pushing the car ALOT more in the very near future. I may just add another 255 to the mix, but when the 400 is another 40 bucks (as of now), i see no reason why not to run that. I may switch the 255 to boost a pump setup. I'm planning a swing arm to be able to mount the pumps together. Aeromotive... i don't like them anymore. Id rather just dump a Weldon on there. But ill cross that road when it comes. Hot side is done and tacked. Ill upload pics later on this week.

TwinTurboROC

Don't worry guys, I didn't forget about this. I got a race against one of my buddies in a week or 2, then ill let the cat out of the bag. I just don't want to put everything out there before that.

Bullydawg

iTrader: (7)

Looks good! Can't wait to see it done!

TwinTurboROC

Ok I got most of the pics of of my phone. More pic to follow as I get time.

Lets start off with a few parts.

So I found out this happened



Had theses laying around. 2 inch summit drop springs.



Had to tie the isolators down



And the stance of the car after the front install. Dropped another half inch to and inch after i rolled it back and forth a few times.




OK now for some parts and goodies.

The correct wastegate (vband mount)



Took it apart to make sure everything is ok. No loose parts or torn diaphrams. Free movement of the piston in its bore etc.



Some super nifty V bands.



Interlocking Flex pipes.



Close up shot of the interlock.



TO ALL TURBO USERS. These are the type of flex pipes you us use BEFORE the turbo. The ones that have double sided steel mesh will eventually burn out if to close to the turbo.

Continuing in the next post.

TwinTurboROC

OK now on to the manifolds. Remember boys and girls trying to keep my A/C and not make my life miserable with plugs and bolts etc. I don't want a headache build. (as if)

And here are the header flanges. Super warped so i flattned them a bit before starting.



Color in the side with a little black sharpie, and file or grind untill you see metal, rinse lather and repeat. Belt sanders also work wonders here.



And so it begins. Setting up the forward facing side first. Top down view. Started with cylinder 4 first.



Shot from the battery tray area looking back



I then pulled it off the car and started to build up tubes, and test fit as I went along.



View from a more flatter angle so you guys can see the path its going.



Number 6 mocked up and ready to roll.



Notice the crazy angle just to avoid the spark plug for number 4



Another shot



Another



And the payoff

TwinTurboROC

So now on to the other nighmares. This was a horror show because of how many things that have to be avoided, while keeping space, while keeping flow... if u wanna call it that.

Cylinder 8 mockup.



Notice the kick back before it starts coming forward.



It's like a jig saw puzzle!!



All mocked up.



Once again another test fit. Looking good so far.




Ok time for cylinder 2 - starting out



Now for that awesome bend



Here comes the pies



All mocked up

TwinTurboROC

Continuing

Here's a shot to show some of the angles needed to "hopefully clear" things.



Passenger side all burnt together - what a pain in the a



MADNESS - hate it or love it?



Another shot - Notice my little red circle in the bottom... looks like i missed a spot to weld.



Clearance with the pass side strut tower brace. IT HAS ABOUT 1/2 inch of clearance, I just couldn't hold the header to the block and take the pic at the same time.



Front 2 plugs. Number 4 has a good amount of space... enough i could run it with just the wire alone, but im put shields on them just in case.


Rear 2 plugs and the stock Head CT switch. The flange pulled a little on this side so im have to re grind it, but i expected as much with the amount of heat I was putting into it.


No space at all.


WAIT A SEC!!!! hopefully I can smuggle a 3.5 inch down pipe here.

TwinTurboROC

And here we go on what I though was gonna be the EASY side. Yeah lol roflcopter. IDK how this managed to turn into a bigger project than anything else.

Setting up tube 7 and the angle and depth.


Brought in cylinder 3 - shots a little blurry but you get the idea.


Semi welded up - Had to do it to see what kind of pulling was gonna happen.


Harsh angles but it had to clear things.


Quick mock up - looks good.


Time for cylinder 7 to get a home.


Another showing a bit of pipe to pipe clearance.

TwinTurboROC

Moving on

I had to re-make tube 7 because it was to close to the number 5 spark plug for my taste. Here is the before, showing the straight entry into the collector. I cut it off and made a much sharper Y entrance into the collector.


Here's a shot showing tube 1 mocked up (not finished) and the middle welded up, and also you can see the modified tube 7. I had to make this tube about 3 times before i got it to where i like it. Remember I am keeping my stock AC and Needed to RE USE the bracket that supports the AC and power steering. It bolts to the exhaust housing so its a big PITA.


Another shot of tube 1 showing the exit out of the head.


This is a top down view.


All welded up


Notice the sharp cutback towards the block as its going down to the collector


Another from the bottom.


And a lil' close up


Hope your enjoying the horror show so far.

TwinTurboROC

I always wonder why I even bother sometimes with the PITA projects.

BTW both headers can be installed and removed without major removal of components. Only spark plug wires and associated V bands. (I also pull the number 3 and 5 plugs because I cave dave install parts, or in short I broke **** installing the header once...LOL)

Both side headers all done. I FEEL HAPPY!!!


Waste gate with some light one it


I can't get over how such a nice knock off this is.


The valve head


Drivers header post collector and V band tacked up (still clears and installs easily) I trimmed the collector and added another bend to it to give me all the clearance I wanted.


Cross over time


Another

OMG TOOLS!!!!! just a lil shot of the 4x6 doing some work.




Oh half way through the build I realized i had enough room DIRECTLY under my passenger side header to run my cross over. But i ended up running it next to the oil pan like i originally planned.



OK also im tired and its like 5 in the morning and I hate cars. More pics to come when I get time to come on the forums for a few hours.

Orr89RocZ

iTrader: (20)

LOL yes i know the feeling!

Good job so far. Lots of pie cuts for bends but it will work

Street Lethal

iTrader: (16)

Great work, looking good...

Blade09

Good work on all those welds! Can't wait to see them all ground down and pretty looking!

TwinTurboROC

Im not gonna grind them down. The entire system is getting wrapped, so only some hi temp pain, wrap, and more paint. Thats why I decided to do almost everything with flux.

Blade09

Gotcha, solid work nonetheless

project89

iTrader: (1)

those would look way to good ground down, and coated , dont hide them under heat wrap

TwinTurboROC

Hahah. Stop tempting me!! But The this whole project is based around keeping the A/C system, Having access to spark plugs, ease of pulling things on and off the car (hence the v bands) and trying to get the maximum amount of power out of that design while being inexpensive. I have more money in V bands than anything else... cept the turbo.

Im only 1000 $ into the project. Got another $300 to finish it up where its street drivable. Then maybe another 500$ in tuning and injectors. (well another 300 for a boost controller and AEM AFR) I admit though some people who have seen the manifolds like them and keep saying keep them out in the open, but honestly I never intended have them visible.

project89

iTrader: (1)

ill have to tempt u just a lil more cause those would look very very nice coated and not wraped once the welds are cleaned up.

not sure what car ur putting those in but i see u have a black and a blue one in ur sig pic.

they make a turbo black coating, they also make a turbo blue coating, so u could have them match the car

TwinTurboROC

Haha, if you read the first post its for the blue car

I was thinking about hitting it w some hit temp aluminized and heat cycling it a few times if im not gonna wrap it. I could care less about the colored coatings. Im a fan of polished things...and Chrome. Oh and anodized things.

project89

iTrader: (1)

yeah i knew u mentioned what car i was just to lazy to go back and look.

i just think those would look way to nice all ground and smoothed out to hide under wrap .

when i built a sheetmetal intake for my v6 car everyone told me not to paint it or clear coat it and it looked badass. i didnt listen and painted it, it looked so much better bare aluminum

TwinTurboROC

well remember this is all just BS mild steel. If it was Stainless I would consider it alot more... I still dont know yet. meh.

Street Lethal

iTrader: (16)

Updates...?

TwinTurboROC

Yep. Everything was together for a quick test. Took everything apart for some cleanup and paint. My god that **** spooled faster than I expected. Still got to fab up spacers for the ac bracket. I just started a new job so I don't got much time to upload
Pics and write things. As it stands I haven't touched a computer for a week and a half straight. And my pos iPhone doesn't like to upload pics at all. I still have to order a bov, injectors and an ostrich. Oh yeah and I should get my own wideband to. Sad part is after about a week after that its comming apart for some header wrap and heat shielding. I still have some odds and ends to build like a heat shield for the starter and just regular operational ****. It gets toasty under the hood ATM so I have to also get a turbo blanket. But before any of that I got a mini diy brake bend rig (sheet metal bender I want to build. But as usual no time. I'll try to do a small update this weekend. Till then love peace and chicken grease.

FSTFBDY

iTrader: (33)

Nice. Looks good. I remember how much a PITA the D.side was to make when I did a build from scratch.

As others said DONT wrap em. Ceramic coat the headers. You can even do them yourself.
Get a 8oz bottle of silver and a 8oz Bottle of Turbo Black from NIC indistries. They even make air dry that will cure on 1st heat cycle.

Street Lethal

iTrader: (16)

... ????

cIaRmOaCrZo

i dont see any of the pics......did he delete them? or is it this computer lol

Street Lethal

iTrader: (16)

Pics are all still there...

LilJayV10

iTrader: (5)

Looking great. I am seriously considering turbo'ing my 89 T/A.

One question, how in the heck did you make the headers. I mean the bends and cutting. This is something I have always wanted to do but have been to scared to do it.

Street Lethal

iTrader: (16)

You cut little pieces of the tubing in degrees to make it conform to the shape that you want. It takes so much freaking patience because one primary alone can take quite a long time, but very rewarding when all is said and done though. Go for it with your '89...

LilJayV10

iTrader: (5)

I guess its one of those things you just have to start messing with till you figure out how it works. How are you cutting such short sections of the pipe, with the stationary band saw you post a pic of?

Z28ricer

iTrader: (2)

You adjust the angle on the chop saw to what you're after, cut the end of the pipe, rotate it 180* and feed it so that it cuts it at the thickness you're after, then make the cut.

If you dont have an adjustability for angle on the saw you're using, you can make a plate that holds things at the correct angle, makes for easy duplication of cuts on making things like merge collectors.

Though for the majority of the header pipes you'd be a lot better off getting a header cut-to-fit kit and then working with that, then if you REALLY have to, do the pie cuts.

Then instead of something like this:
http://i239.photobucket.com/albums/f...x/EPSN4936.jpg


You make something more like this:
http://i239.photobucket.com/albums/f...x/DSCN0998.jpg
http://i239.photobucket.com/albums/f...x/DSCN0997.jpg