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Old 06-23-2012, 10:06 PM   #11
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Looking good! Got me amp'ed to do some work.
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Old 06-24-2012, 08:06 PM   #12
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Finished up the wastegate flange tonight. I know the manifold isn't beautiful, but it was also one of the first welding project I ever did 5 years ago. So, don't judge too harshly on those old welds. I've had to repair a couple cracks, but overall it's actually held up very well.. it's just ugly. :)
Next up is the return line from the wastegate to the exhaust. Last fab stuff is some minor modifications to the intercooler pipes, coolant lines to the turbo then ready to dial in the tune!

38mm flange for Tial:






I haven't positioned the vacuum ports yet.


Fairly direct shot to the downpipe from the wastegate. That is tomorrow's project.
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Old 06-24-2012, 08:08 PM   #13
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Looks good man.
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Old 06-24-2012, 08:15 PM   #14
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Quote:
Originally Posted by Roushturboedzx3 View Post
Looks good man.
Thanks sir
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Old 06-24-2012, 08:25 PM   #15
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Why do you wanna do the recirc wastegate, more of a sleeper ?
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Old 06-24-2012, 08:30 PM   #16
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Why do you wanna do the recirc wastegate, more of a sleeper ?
Don't want the noise and don't want to deal with picky city popo. Still considering a cutout for the track.
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Old 06-24-2012, 09:21 PM   #17
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I decided I want to use a flex pipe between the wastegate outlet and main exhaust pipe. I'll work on something else until that arrives.
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Old 06-27-2012, 07:57 PM   #18
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Flex pipe to go between the wastegate and downpipe. This size is surprisingly difficult to find! Found this on Amazon.
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Old 06-29-2012, 09:29 PM   #19
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I'm making progress on the wastegate return pipe. I determined I do not like the angle of entry into the exhaust, so I'm going to cut off that angled part and make it more of a 45 degree entry instead of 90.
Overall I'm pleased with the progress, considering how little time I'm able to put into it.
I ended up making a 38mm flat flange because I was short one. The moral of that story is: keep everything. :) The piece of metal was from my buddy's F150 diesel that we replaced the water pump in 5 years ago. It was part of the A/C bracket.

Tomorrow I'll finish the wastegate return, modify the hot side intercooler piping, modify the ambient pipe, and if I have time hook up the water and oil lines to the turbo.

Sorry for the cell phone pics tonight.

The A/C bracket, I mean flange:


Wastegate return


This is the angle I'm going to tweak to more of a 45:


Where that flange was used:
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Last edited by sutyak; 06-30-2012 at 10:15 PM.
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Old 06-30-2012, 08:18 AM   #20
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Looks great. Can't wait to see everything finished.
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