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Old 07-29-2007, 01:40 AM   #39
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Join Date: Sep 2004
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Location: Fairmont, WV
What I Drive: Turbo 04 DSG Mach 1

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Day 12

Start time: ~11:00am
End time: ~1:30am

I finished up the exhaust today.
It took way, way longer than I anticipated.
Getting everything aligned just right by myself, on the garage floor, and making my own hangers from scratch was pretty tough.

I ran into an alignment problem with the IHI wastegate.
Apparently I had the test-fit turbo all tweaked and didn't even notice it.
So tomorrow I have to figure out a way to get my good one aligned properly.
I needed the compressor outlet to face a different direction than on the Tbird so I turned it.
I'll post tomorrow what I come up with.

I also weighed parts today since I'm basically finished with all fab work.
Measurements are with a bathroom scale, so accuracy is definitely not dead on.
Exhaust: 31.4 lb
Header: 17.4 lb
Plastic air intake stuff: 7 lb
Total: 55.8 lb

IHI turbo: 12.8 lb
Header: 9.4 lb
Down pipe: 5.8 lb
Cat: 6.4 lb
After-cat: 23.2 lb
Intercooler: 8.4 lb
IC pipes: 15.2 lb (steel and painted)
Total: 72.8 lb

Total does not include weight of couplers, clamps, air filter, oil lines, brass fittings, gauges, and intercooler.
Estimated added weight: ~40 lb


Mid section of exhaust:

Cat with new hanger.
Looks odd but works great.

Full exhaust painted:

Wastegate misaligned!
Life goes on, will fix tomorrow.
'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 10:13 AM.
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