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ZZ's '97 GTS- Single Turbo Build

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Old February 2nd, 2016, 09:43 PM   #81
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I did the same thing with my wire harness. I welded a bigger tube up front as the stock one needed to move an inch or so. I fed the wire inside the tube. That thing was always in the way before.

Nice header work.
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Old February 2nd, 2016, 10:08 PM   #82
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On your turbo mount, is it only connected via the oil drain or will the mount also connect to the clock ring on the compressor housing? How will you accommodate for the sway bar movement?


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Old February 2nd, 2016, 10:59 PM   #83
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On your turbo mount, is it only connected via the oil drain or will the mount also connect to the clock ring on the compressor housing? How will you accommodate for the sway bar movement?


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No clock ring on the compressor housing or the turbine housing. they are both v-band. Also, I don't think your supposed to mount to the compressor housing ring due to the clearances, only on the turbine housing if you want to use it as a turbo mount.

As for accounting for sway bar movement, I'm installing brand new poly mounts, so I'm assuming movement outside of a slight twisting will be negligible. As for the twisting motion, between the two poly mounts, I don't know that there is much twist actually occurring. It's something I considered but I don't have a good way of nailing down the amount it will twist, or if it can be ignored for my purposes.
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Old February 2nd, 2016, 11:35 PM   #84
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I know what how things will escalate exponentially for power levels over that goal. I would rather build a stout 900-1000whp car and keep it together and have fun than be fixing it everytime I take it out. I had to turn off my ego and decide I wasn't going to be king of the world, but at this point in the hobby for me it is more about the fun of building something unique and fun than to be top dawg (which I'm not capable of anyway).
That's how we feel as well, build it to hopefully be able to stand up to a lot more and enjoy driving the car. Either way you are doing a great job! Thanks for posting the pics up!

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Speaking as a newcomer to the 1000 hp world, this level of power is insane. I'm at low boost still so probably at 750-800 whp, and flooring it for any length of time is just scary. I need to find an empty airfield to drive this thing. Can't imagine what it'll be like once the boost is at it's high setting and I'm at 930 whp.
Haha, we had the same feeling as well, we didn't even want to floor it on the high boost setting scared of what might happen. However that wore off pretty quickly

They have some air strip event here, I think around spring. Hopefully we are up and running then, maybe we can check that out and hopefully have enough space to let her stretch her legs so to speak.

Edit: Found it! It's June timeframe: http://pikespeakairstripattack.com/
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Old February 3rd, 2016, 02:28 PM   #85
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Yeah, I found that event online, I hope it is being held this year, I'd love to try it out there.
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Old February 3rd, 2016, 03:10 PM   #86
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The swaybar will rotate the most under even compression and droop of the front wheels. If you have room it may not be a bad idea to run a brace from your turbo bracket to the chassis crossmember to take the rotational load of the turbo off of the exhaust manifolds, so your turbo isn't balancing on the swaybar .
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Old February 13th, 2016, 09:46 AM   #87
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This has been one of the most interesting build threads I've ever come across. Great work!!
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Old February 13th, 2016, 02:55 PM   #88
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Nothing short of fantastic.
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Old March 4th, 2016, 12:47 PM   #89
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My mind hit the panic button on March 1 and realized I have very little time to get this thing functioning for summer.

I have an extremely long list of things to do to this before it's ready to hit the road, so decided to pick a low hanging fruit this week.

I had some BC coilovers waiting in the basement I bought on Black Friday from RSI so I decided to throw those on and check something off the list. Of course as usual, this simple 2 hour project escalated to taking much longer.

Front suspension. A little bit dirty. 20 years of grease, road, and track debris. Figured while I was in there I couldn't neglect it any longer.

Before, with stock Konis and Eibach springs.



While I was in there I noticed another problem. Sway-bar links were toast. They seemed to be functioning fine but the boots were beyond repair.



Shocks/springs removed, and some serious cleanup done via a scraper, wire brush, and a lot of Gunk degreaser.



Little bit of dirt and oil knocked loose.



Took out the old sway bar links, and ordered some MOOG replacements.

Old and New:



Busted out the new coilovers. Much smaller and lighter than the stockers.



New sway bar links and coilovers installed in my freshly cleaned a-arms. Much better! Not as clean as Dave's but I can live with that.



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Old March 4th, 2016, 06:48 PM   #90
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looks great
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Old March 7th, 2016, 08:45 AM   #91
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I was planning on getting a bunch of time this weekend on the car. Surprise, I didn't

Regardless, I was able to get some work done on the manifolds.

I wanted the primaries to sit approximately 50% of the way into the 3/8" flange for welding, but when you have 5 cylinders and they all have to line up, it's very difficult to keep everything square until it's tacked.

In order to do this, I 3D printed some manifold spacers to sit into the exhaust ports and be a hard stop for the primary to rest against.





With that done, I was able to move onto making the last primary which was a huge PITA. I had very little room for the cone portion to transition the 1.75" primary to 2.25" log. Not to mention, the D-port had to be perfectly perpendicular and then the height of the 90 had to stay centered on the log for correct fitment.



Now that the last primary was completed, I could work on the actual log.

First, I cut the tube to length, then roughly marked each primary location.







With all 4 holes drilled, I could move onto final alignment and tack welding.



From concept to reality. Not too shabby for my first try. It's by no means perfect but for the first time I've ever really worked with metal fabrication, I'm not going to complain.



For fun, I threw it on the car to check clearances and see where I want to add the v-band.



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Old March 7th, 2016, 10:50 AM   #92
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Do you think the poly mounts will be ok with the heat? Great work.
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Old March 7th, 2016, 11:41 AM   #93
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Do you think the poly mounts will be ok with the heat? Great work.
On the engine mounts? or the turbo mounts i'm planning?

The engine mounts should be fine. I have heat shields for them and I will be coating and wrapping the log manifolds in DEI exhaust wrap.

As for the poly turbo mount.. never really thought about it but I'm thinking it will survive. I think it will be okay since the turbo will see fan air and the mounts will be below a 3/8" steel plate.
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Old March 7th, 2016, 12:46 PM   #94
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Looking great as usual. It's going to be a very nice setup.
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Old March 7th, 2016, 01:33 PM   #95
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Logs look like proprietary rights to me lol great work Zach now patent them and start selling them like the big shops do lol
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Old March 7th, 2016, 02:20 PM   #96
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Logs look like proprietary rights to me lol great work Zach now patent them and start selling them like the big shops do lol
Haha, no thanks. Anyone else who would want to do a front mount single turbo just to be unique would have to be insane.

I'll sell them as a fabricator kit where you have to do all the work though!
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Old March 7th, 2016, 05:32 PM   #97
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Hahaha
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Old March 23rd, 2016, 08:54 AM   #98
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Finished up both exhaust manifolds over the last week.

Learning to TIG weld with zero on-site correction and having never touched a welder of any kind in my life before this project, it's been very challenging to learn. I've got a long way to go before I'm laying beautiful welds but I'm super proud of myself for taking the plunge and making this happen on my own.

On the driver side, I have a 4" aluminum downpipe coming off of the turbo, and it needs to squeeze under the hotside and above the A/C compressor. It's a very tight space so I had to jog the hot side up immediately after the last primary to make as much room as possible.



You can see what I am talking about here with the 4" downpipe shoved in there to make sure it will fit.





Welds are not perfect but they will work just fine.





Both are done, cleaned up, and ready for some header paint and DEI wrap!

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Old March 23rd, 2016, 10:02 AM   #99
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Fantastic welding for a first timer!

Nicely done!
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Old March 23rd, 2016, 10:08 AM   #100
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your welds look fucking awesome
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