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Old 07-24-2007, 06:17 AM   #4
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: Turbo 04 DSG Mach 1

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Start time: 11:30am
End time: 3:00am

Day 3

Well I didn't work on intercooler piping today.
I got an itch to work on the exhaust so I did.
I hacked off the stock exhaust and started with my own.
I spent a lot of time trying to figure out where to mount this monster Magnaflow muffler I bought.
In retrospect I kinda wish I would have either gone shorter, or more narrow..
Shorter would have fit in the position of the stock resonator..
More narrow and I could have placed it where I thought I was going to, and more importantly higher and tighter under the car.
This beast is going to hang down a bit. Maybe 2" max.
No baja competitions for me I guess. :grin:
My car isn't lowered so I'm not worried about it.

The catalytic converter was a pain to position..
This was due to having to move the muffler closer to the front of the car because to lack of width where I originally wanted to mount it.
I had to trim a couple of the corners of the cat to help with fitment.
I ended up cutting out the 2 stock hangers to fit the cat in that spot.
I'll reuse those same hanger rods but I'll widen them to accomodate the cat size.
I also ended up welding the 2nd O2 sensor bung in the front of the cat.
That isn't what I originally had in mind, but I think it'll work fine.

I started painting parts today!
Anything that gets really hot got painted with Rustoleum 1200* paint.
I also had some Ford Twilight Blue that I picked up from Advance for like $1 a while back so I painted some other stuff with that.
The blue doesn't really match my car, but it looks awesome anyway. :grin:
Everything looks 100x better painted.

Paint prep:
All parts, even if they "looked" clean, got at least a thurough scrub with mineral spirits.
Many parts needed a wire brush or bench grinder wire wheel taken to them first.
After the parts actually look like metal again is when I use the mineral spirits.
Then a final wipe down with a paper towel to confirm no dirt is left.

After a revelation I emailed my tuner and he said this will work just fine:
I'm going to leave everything from this build installed, he's going to mail me an SCT xCalibrator 2 unit with 3 "starter" tunes in it.
Basically it will handle my 55lb injectors and disable the 2 rear O2 sensors.
I want to run around for a couple weeks with the turbo plumbed up, but the wastegate disconnected so I don't actually build boost.
That way I'll have plenty of time to fix any type of leak before driving to my tuner for the "real" tune.:clap:

I really think I'll work on intercooler piping this time!
I'll also be spending time online and phone ordering last minute parts.


First off.. you turbo guys.. is this piece I'm pointing at supposed to be loose?
The actual shaft has NO play and spins freely.

Cool air side:

Tiny turbo!

Downpipe is complete minus paint!

As requested, a pic of my stock engine.
Ignore the lack of exhaut manifold. :grin:

Header complete!


.. and painted!


Muffler hangs down a bit:

Painted parts:
Yes that's a gen 1 Talon bov sporting Ford blue.
I'll try to get better pics of the blue tomorrow.

Stock 2006 Focus exhaust:
'04 Mach 1. Built. Turbo. 667whp/631wtq
'06 Focus. Built. Turbo. WMI. (sold)
'03 Mach 1 : 12.61 @ 106.59 (sold)

Last edited by sutyak; 09-05-2007 at 09:59 AM.
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