My BW S475 project... lots of pics.
So.. i finally sold my greddy t78 kit and went for a borg warner s475 with 1.10 A/R.
Car summer 2008 http://www1.garaget.org/archive/92/9...893-916922.jpg [youtube]http://www.youtube.com/v/uslGUyz3a5A&hl=sv&fs=1[/youtube] 2007/2008 winter build up with new fuel system, weldon 2035 pump and 6x1680cc injectors http://www.molnsatra.se/bil/f3.JPG http://www.molnsatra.se/bil/fuelrail/2.jpg 2007/2008 i also installed the t78 turbo kit and made a new manifold. http://www.molnsatra.se/bil/tryckror/6.JPG The car was dynoed a couple of times in 2008 and at 21psi it made 548RWHP on E85 tuned by myself. As usual that was fun for a few weeks and now winter has arrived and my fingers itches like hell! Two weeks ago i received some material to work with, i've been welding some aluminum but never done anything useful with stainless.. First off, i did this to be able to make.... http://www.molnsatra.se/bil/turbo/1.jpg this fixture of the new manifold. http://www.molnsatra.se/bil/turbo/2.jpg |
I bolted on the flanges and started to measure and measure, and finally cut!
http://www.molnsatra.se/bil/turbo/3.jpg Both runners made. http://www.molnsatra.se/bil/turbo/5.jpg http://www.molnsatra.se/bil/turbo/6.jpg http://www.molnsatra.se/bil/turbo/7.jpg http://www.molnsatra.se/bil/turbo/8.jpg http://www.molnsatra.se/bil/turbo/9.jpg i finally got to weld :) http://www.molnsatra.se/bil/turbo/24.jpg http://www.molnsatra.se/bil/turbo/10.jpg http://www.molnsatra.se/bil/turbo/22.jpg http://www.molnsatra.se/bil/turbo/23.jpg |
finally...
http://www.molnsatra.se/bil/turbo/11.jpg http://www.molnsatra.se/bil/turbo/12.jpg http://www.molnsatra.se/bil/turbo/13.jpg THe new turbo on the new manifold, the fixture did its job, it is tight but it fits :) http://www.molnsatra.se/bil/turbo/14.jpg http://www.molnsatra.se/bil/turbo/15.jpg http://www.molnsatra.se/bil/turbo/16.jpg now the wastegates, 2 synapse 40mm wastegates. http://www.molnsatra.se/bil/turbo/17.jpg First wastegate there.. http://www.molnsatra.se/bil/turbo/18.jpg Space was a big issue here, it was hard to make room for both of them, i probably got the manifold on and off the car 30 times before i got it right. |
Welding the flanges..
http://www.molnsatra.se/bil/turbo/25.jpg zoom zoom zoom zoom... :D http://www.molnsatra.se/bil/turbo/26.jpg http://www.molnsatra.se/bil/turbo/27.jpg http://www.molnsatra.se/bil/turbo/28.jpg Time to weld. http://www.molnsatra.se/bil/turbo/29.jpg http://www.molnsatra.se/bil/turbo/30.jpg both of them welded. http://www.molnsatra.se/bil/turbo/31.jpg Welded backside of the flange. http://www.molnsatra.se/bil/turbo/32.jpg Both wastegates mounted :) http://www.molnsatra.se/bil/turbo/33.jpg http://www.molnsatra.se/bil/turbo/34.jpg |
Got a bit tired of all stainless so got some aluminum work done.
3.5" to 3" http://www.molnsatra.se/bil/turbo/a1.jpg http://www.molnsatra.se/bil/turbo/a2.jpg got some bends on there aswell,. http://www.molnsatra.se/bil/turbo/a3.jpg http://www.molnsatra.se/bil/turbo/a4.jpg zoom zoom zoom http://www.molnsatra.se/bil/turbo/a5.jpg http://www.molnsatra.se/bil/turbo/a6.jpg Something like that! http://www.molnsatra.se/bil/turbo/a7.jpg http://www.molnsatra.se/bil/turbo/a8.jpg so far so good. Lets weld some more.. :P http://www.molnsatra.se/bil/turbo/a9.jpg http://www.molnsatra.se/bil/turbo/a10.jpg |
Getting close!
http://www.molnsatra.se/bil/turbo/a11.jpg http://www.molnsatra.se/bil/turbo/a12.jpg Lets do some stainless again... beginning of the downpipe 5" is kind of big... http://www.molnsatra.se/bil/turbo/d1.jpg http://www.molnsatra.se/bil/turbo/d2.jpg got a reducer on there. http://www.molnsatra.se/bil/turbo/d3.jpg time for some welding.. http://www.molnsatra.se/bil/turbo/d4.jpg zoom zoom zoom zoom http://www.molnsatra.se/bil/turbo/d5.jpg http://www.molnsatra.se/bil/turbo/d6.jpg finally things are comming together. http://www.molnsatra.se/bil/turbo/d7.jpg http://www.molnsatra.se/bil/turbo/d8.jpg |
Making the rest of the downpipe.
http://www.molnsatra.se/bil/turbo/dp1.jpg http://www.molnsatra.se/bil/turbo/dp2.jpg Welded http://www.molnsatra.se/bil/turbo/dp3.jpg Welding it to the downpipe. http://www.molnsatra.se/bil/turbo/dp4.jpg Almost there :) http://www.molnsatra.se/bil/turbo/dp5.jpg http://www.molnsatra.se/bil/turbo/dp6.jpg Yes! http://www.molnsatra.se/bil/turbo/dp7.jpg Now i need to get some flanges to be able to continue,, So far so good! http://www.molnsatra.se/bil/turbo/dp8.jpg more to come.. |
looks very nice and great work.. im on a simliar path.. dam that turbo is going to be a tight fit. do the wastgates stick out from under the car at all?
|
Originally Posted by turboR1
(Post 8775742)
looks very nice and great work.. im on a simliar path.. dam that turbo is going to be a tight fit. do the wastgates stick out from under the car at all?
They are about an inch under the subframe |
Very Nice...
Now i know why you need upgraded axles.. LOL... |
wow this is a very nice build
what are your power goals? also, what kind of porting do you have? |
Nice job and fast as usual Gustav "thumbs up"! So you kept it 3" the last way? Must try to locate a good air filter for you or as we speaked about a cold air boxed system maybe is the way to go? Now to a question to all you BW 475 lovers, what kind of hp at 20 psi boost and at what rpm is Gustav gonna make? This would be on a RotoTest hub dyno. Myself i think 600 rwhp@7700 rpm@20psi!??
/Lasse |
nice work, i wish i had skills like that.
|
600 is alittle high for only 20 psi esp since this turbo doesnt start moving until 20+psi.. prob 525 is a better number at 20psi. you have to run big boost with this turbo to make power.
|
Veryyyy nice! the welding looks great, lets hope it holds the weight of that beast :)
|
The intercooler piping from the compressor outlet has too many bends IMO. I would have opted to a larger single wastegate and put it as close to the turbine inlet as possible... You're on the right track, we all just do it differently. Beautiful port matching on the Excessive LIM (I bet you hated how bad they come cast too...) Also, Excellent work on the manifold! :)
|
I like you LIFT..
|
Great work, wish I knew how to weld...
|
Originally Posted by Lasse wankel
(Post 8775905)
what kind of hp at 20 psi boost and at what rpm is Gustav gonna make? This would be on a RotoTest hub dyno. Myself i think 600 rwhp@7700 rpm@20psi!??
/Lasse |
Originally Posted by Japan2LA
(Post 8776050)
I like you LIFT..
|
Originally Posted by Japan2LA
(Post 8776050)
I like you LIFT..
-J |
Originally Posted by Lasse wankel
(Post 8775905)
Nice job and fast as usual Gustav "thumbs up"! So you kept it 3" the last way? Must try to locate a good air filter for you or as we speaked about a cold air boxed system maybe is the way to go? Now to a question to all you BW 475 lovers, what kind of hp at 20 psi boost and at what rpm is Gustav gonna make? This would be on a RotoTest hub dyno. Myself i think 600 rwhp@7700 rpm@20psi!??
/Lasse |
Originally Posted by turboR1
(Post 8775924)
600 is alittle high for only 20 psi esp since this turbo doesnt start moving until 20+psi.. prob 525 is a better number at 20psi. you have to run big boost with this turbo to make power.
i will be using this turbo too in a little while and cant wait! |
Thanks for nice comments,
I dont want to speculate about power, time will tell, will put the car on the dyno when im finished. With the greddy turbo the car put down 499whp @ 17psi pump gas, 506whp@15psi E85, 548whp@21psi E85. The goal with the car is to run a 10 on 1/4 next summer :) the LIFT is my best tool :lol: |
real nice. the welds look awsome
|
All times are GMT -5. The time now is 01:29 AM. |
© 2024 MH Sub I, LLC dba Internet Brands