FINAL.. Mock-up of Intercooler Pipes

I have run these damn pipes every which way under the sun. Now I have settled on what I want to do. Running the pipes this way gives me symmetry and also allows me to run the ABS unit in there (but the ABS is still getting ripped out). This is important to me because I’m not ripping out the ABS myself, my speed shop is. So I need to be able to get the car to the speed shop without having to have two sets of intercooler pipes.

Drivers side and Passenger side both have:
– 1 x 90 degree bend
– 3 x 45 degree bends

I know that the cold side runs over the turbo, but it was like that before I started this project so I am no worse off

I wrapped the pipes with duct tape so I could better see what it will look like.

You can also see where I’ll have a mounting plate welded on for the BOV in the pictures below:

I think this week I’ll start talking to some powder-coaters on getting the rest of my stuff finished. I’m also leaning towards getting a new Power Steering pump that doesn’t have a press on pulley so that I can run Unorthodox polished pulleys for my Alternator and Power Steering.

I figure if I already have it tore apart, I might as well do it up right.

Another Day in the Garage

I started out the day working with many different intercooler piping variations.. switched up the hot side and cold side.. moved them back.. tried various different routes.

Basically I’m trying to figure out a way where I can pretty much get away with 90’s and 45’s in the pipe. It will just make it that much easier for fabrication.

I was continually thinking about:
– will I have enough clearance for the coolant tank
– will I have enough clearance for the intake
– will I have enough clearance for the BOV
– bla.. bla.. bla

Then I realized I was doing it all bass-ackwards. I figured out that I should mount all my obstacles and then make up my intercooler piping to go around them.

So this afternoon I made my aluminum mounts for the forge coolant reservoir. I fabricated them out of two pieces of stock Aluminum to provide both vertical and horizontal support. It becomes kind of a “U” with support by bolting it to two spots on the block. I’ll also be able to send the mounts out to my polishing guy to get them as shiny as the tank.

Here are some pics of the tank mounted. I still have a bit of clean-up work to do around the corners of the mounts to make them smooth.

Blasted and Polished Parts

This morning I picked up some more of the media blasted parts. Some will hopefully get chrome, and some will get powder coat….

I also picked up my FPR bracket, BOV and valve covers from the polishing shop at lunch today. ba.. ba.. ba.. BLING 🙂

Fuel Line Routing

I’m planning to run 45’s off of the FPR and the rear of the rails. I just put the fittings on there checking for clearance

The picture below shows how I am thinking about running my fuel lines.

For powder coating am I better off going with a darker grey with some metallic fleck? I just don’t want it to be too close to my engine bay color because it will look like I was trying to match it.

Disappointing Bending

Well it looks like the tube bending is a bit of a bust.. they usually need to do a run of 100+ pipes and don’t do one-off items.

I think I’ll have to go the suggested route with a piping kit and welding. I’ll have to hit up some welding contacts. I guess I’ll have to figure out what bends I’m going to need.

I dropped some more parts off for media blasting this morning. As soon as I get them back I’ll be taking them to the powder coaters. Hoping to go “Black Chrome” for:
– Alternator
– Brackets for Alternator/Power Steering
– Misc brackets/bolts
– Upper Radiator supports

Tomorrow I’ll be dropping of a box of items to get polished at the shop Wayne’s been using for his polished bits.

Mounting and Tweaking

I headed out the garage this morning, cranked up the Billy Talent, and got to work

First order was to create a mounting bracket for my fuel pressure regulator. I had some stock aluminum kicking around so I started to work with it. The idea was to make a bracket that would hold the FPR above the pitch mount.

I had to trim some of the FPR bracket to get it to fit with what I wanted to do, but in general it turned out pretty damn good. I just have one more hole to drill to put a bolt at the top of the bracket going into the wiper area.

I’ll end up getting the bracket polished to a mirror shine with the rest of my stuff.

Media Blasting and Fuel Pressure Regulator

I was able to pick up the cleaned up power steering pump and power steering and alternator brackets. They cleaned up quite nice in all their raw aluminum glory

I also was able to pick up the FPR, distribution block and o-rings today from the good old post office.

I’m hoping to get some time this weekend to start putting a few things together.

Fuel System Parts

I made a quick trip down to JRP to pick up some various braided and silicone hoses along with some AN fittings that came in.

Also the fuel pressure regulator and Y-block have now been ordered. It turns out that I already have most of the AN ORB fittings that I need. I already have 4 -6AN to -6AN ORB fittings that are on my Agency Power distribution block. So I will only need one more of them. I also have a -6AN to 3/8 npt for my existing distribution block. So I picked up some new -6AN o-rings for a fresh seal.

They should be here within the next week

New Parts have Arrived

So some new parts arrived today. The Forge coolant tank and the Agency Power turbo inlet pipe. Which first created a sense of panic because I was like WTF!! this intake pipe doesn’t fit. Then I took a look at the APS turbo inlet pipe installation instructions and popped on the old intake manifold to see that it actually attaches to the OEM intake manifold. I was trying to figure out how to make it fit between the TGVs and the power steering pump.

Turns out it isn’t supposed to fit in there, instead rest on top of the power steering pump and hang from the intake manifold. So I put it in place and put the Magnus intake manifold back on there and it actually pins it in place so that it sits nice and solid in there. So I was feeling much better

I also reversed the flow of the intercooler piping. You can now see that the cold side comes in from the drivers side and the hot side goes over the turbo. I still have a bit more to do on the passenger side piping but it looks like it will work.

I also am now going to put the power steering reservoir where the AC compressor used to be, and the coolant reservoir over where the BOV is.

When you look at the pictures below just picture a nice polished alternator, turbo heat shield, BOV and intercooler piping.