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ZZ's '97 GTS- Single Turbo Build

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Old April 27th, 2017, 02:06 PM   #281
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Shortly after the full first street tuning session I was looking over the car and found this.



There is a rather large internet debate about whether you can run aluminum exhaust right off the turbo. I guess I lost this round haha. Many of my local friends do it without issue but I have a 90 right off the turbo and I don't think it's helping.

The 11 gauge pipe was unharmed, but the cast aluminum flange, which is much thinner where it sleeves over the pipe did not survive. I suspect I could give it another go with a billet flange and welding the inside, and outside (first time I only welded the outside).





Aluminum literally melted to the v-band :0



For now, because I don't want to keep fixing this, I remade the first half of the exhaust in stainless steel. I tore down the entire turbo setup, exhaust manifolds, draining fluids and all, fit up a new SS exhaust, fully welded it, and re-installed in 1 night so I could make a car show the next day.

Fitting new stainless steel pipe:



Bit of a tight squeeze!



Fully welded:



And all back together:



I also added the aluminum power steering reservoir for some extra safety since it is near the exhaust and the stocker is plastic. Working good so far!
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Old April 28th, 2017, 12:39 AM   #282
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Looks great!
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Old April 28th, 2017, 01:08 PM   #283
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Wow, looks like the time you spent ensuring the system was "workable" paid off based on how quickly you were able to replace the down pipe. Looking very cool; what an awesome project.
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Old April 28th, 2017, 02:44 PM   #284
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We need some vids of some good pulls!
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Old April 28th, 2017, 03:59 PM   #285
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Impressive! Congrats!
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Old May 7th, 2017, 11:03 AM   #286
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That's quality use of your time right there! Really well done.
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Old May 7th, 2017, 06:40 PM   #287
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Nice work and all in one day!

I would periodically temperature check the ps reservoir with a temp gun, especially after hard pulls or longer driving periods just to make sure it's not getting too hot.
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Old May 12th, 2017, 03:05 PM   #288
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All sorts of updates today from the last few weeks.

One of the last steps of the car was to put the hood back on.

There were 2 potential "interferences" that I knew could hurt me. I went 0 for 2.

First was the coolant reservoir I had made. I knew right after installing it that it looked way too high, but it was too late so I figured I would run it until I put the hood on and fix it as necessary.



I pretty much figured out that the top of the pressure cap needs to be even or lower than the wheel well bulge.



With that I needed to cut it down.







Welded and patched back together at a much lower height.



Much Better.





Second fail was the ECU location I chose for our custom MS3 Pro setup.

I put it on the rear area on the driver side. Turns out the hood is NOT symmetrical and there really isn't any room there.

Here was the ECU setup before.



I at some point had removed the washer bottle reservoir.

The bolt riv-nut still resided there so I decided to fab a bracket out of some scrap aluminum I had laying around to find a new spot for the ECU to fit.

Bracket designed and fabbed





Mounted:





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Old May 12th, 2017, 03:05 PM   #289
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Next, I finally received my aero from Autoform. Rear T/A spoiler and front T/A splitter.















Lastly, with the hood back on, we were able to get the car street tuned on 93 octane and then last night on E85! Still need to put it on a dyno to verify numbers, but the car is pulling HARD on 13 lbs. Cooling seems to be very good as well so far. If the car is moving, it sits at 180. It has done back to back to back pulls and the temp is dead steady. If it's in standstill traffic, it crawls up to about 195.

Here's a video of some pulls on E85:


Last edited by ZZ SRT; May 12th, 2017 at 03:59 PM.
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Old May 12th, 2017, 03:29 PM   #290
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Nice work bud! Remove the "s" in http, also cut and paste the direct link of the page, not the embedding link.

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Old May 12th, 2017, 03:59 PM   #291
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Originally Posted by Twinscrewd View Post
Nice work bud! Remove the "s" in http, also cut and paste the direct link of the page, not the embedding link.
Thanks!!!
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Old May 12th, 2017, 05:19 PM   #292
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Car looks awesome! The labor of love was worth it, enjoy it!

Don't forget updates with a few kill vids.
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Old May 12th, 2017, 05:58 PM   #293
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If you need a nice road to run it on, give me a call!
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Old May 16th, 2017, 11:39 AM   #294
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Nice work ZZ! congrats on an awesome build!
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Old May 18th, 2017, 08:20 AM   #295
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Fantastic work Zach!
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Old June 2nd, 2017, 09:41 AM   #296
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A little video I took the other night trying to capture some fireworks.


Last edited by ZZ SRT; June 2nd, 2017 at 10:52 AM.
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Old June 2nd, 2017, 01:17 PM   #297
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"Cool" alcohol flame, bro!
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Old June 2nd, 2017, 01:44 PM   #298
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Cool vid Zach, sounds almost like a V8 from that angle.
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Old June 2nd, 2017, 07:16 PM   #299
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I would be worried that it will melt the paint on the side of the car But seriously looks bad ass.
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Old June 2nd, 2017, 07:26 PM   #300
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I would be worried that it will melt the paint on the side of the car But seriously looks bad ass.
It would take at least 5 years of driving it around every weekend for that to happen.
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