So.. i finally sold my greddy t78 kit and went for a borg warner s475 with 1.10 A/R.

Car summer 2008

[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




2007/2008 i also installed the t78 turbo kit and made a new manifold.


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....


this fixture of the new manifold.

 

I bolted on the flanges and started to measure and measure, and finally cut!


Both runners made.






i finally got to weld

 

finally...




THe new turbo on the new manifold, the fixture did its job, it is tight but it fits




now the wastegates, 2 synapse 40mm wastegates.


First wastegate there..


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..



zoom zoom zoom zoom...





Time to weld.



both of them welded.


Welded backside of the flange.


Both wastegates mounted

 

Got a bit tired of all stainless so got some aluminum work done.

3.5" to 3"



got some bends on there aswell,.



zoom zoom zoom



Something like that!



so far so good. Lets weld some more.. :P

 

Getting close!



Lets do some stainless again... beginning of the downpipe

5" is kind of big...



got a reducer on there.


time for some welding..


zoom zoom zoom zoom




finally things are comming together.

 

Making the rest of the downpipe.



Welded



Welding it to the downpipe.


Almost there



Yes!


Now i need to get some flanges to be able to continue,,

So far so good!


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?

 

Sweet!

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...

 

I'm gonna guess 625hp @ 25~27psi.

 

I was going to say that too.

 

I thought the same thing....

-J

 

i would guess on 91-93 pump gas at 20 psi it woudl be in the low 500rwhp range, like 500-515. I put a little over 500 on 20psi on a GT42, either way both my and his turbo is still not waking up at that leve, it needs to be hin the high 20 to make monster boost.

 

gotham used this turbo on a similar setup right before going under and made 608 @20psi on a mustang dyno. so dynojet numbers is well into 600s.

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

 

real nice. the welds look awsome