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Old 07-29-2007, 01:40 AM   #39
sporadic
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

Posts: 1,261
FF Reputation: 61 sporadic Excellent Standing Member
Buy-Sell-Trade Rating: (12)
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.
Stock:
Exhaust: 31.4 lb
Header: 17.4 lb
Plastic air intake stuff: 7 lb
Total: 55.8 lb

Turbo:
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

PICS

Mid section of exhaust:


Cat with new hanger.
Looks odd but works great.


Full exhaust painted:


Wastegate misaligned!
Life goes on, will fix tomorrow.
__________________
2006 sonic blue zx5 GT2871r turbo.

Last edited by sporadic; 09-05-2007 at 10:13 AM.
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