engine build with pictures

[20vturbo]

I'll have to machine the compressor housing and make that lip smaller I may gain like half an inch there...Next I'll make a mold with relief for the light adjustment and have an intake pipe made out of carbon fiber...Another option may be to chop the light but I am not really at ease with

[dirtybrd]

Thats bad. I dont have a clue. I can only think of modding the back of the light. You might have to lose the option of low beams, re-aim your highs a little lower, and shorten that boot on the turbo side. Just an idea. But from the looks of it, you either have to mod the light or the turbo inlet.

[20vturbo]

Thats bad. I dont have a clue. I can only think of modding the back of the light. You might have to lose the option of low beams, re-aim your highs a little lower, and shorten that boot on the turbo side. Just an idea. But from the looks of it, you either have to mod the light or the turbo inlet.

I'll try to do it whithout touching the light...I can't really get a 3d picture online but it's not that bad Question Does the back of e codes look the same as that light????
I'll try to get the housing machined and loose 1/2" from there...I'll have to find a material to make a mold and on that mold I'll make the actual intake pipe, I'll have the maf and filter sit verticcal behind the radiator...The housing will sit different, the pipe from the turbo to ic will pass where the pump used to be....It will be pain but it's feasable

[dirtybrd]

But sitting behind the rad. it will be pulling in hot air. And Im not sure on the E-codes. For the IC pipe, I just cut out a section/hole of the core support and ran the pipe through it. Just over the A/C line for the condenser. That way you run the TIP under the headlight getting better air.

[20vturbo]

But sitting behind the rad. it will be pulling in hot air. And Im not sure on the E-codes. For the IC pipe, I just cut out a section/hole of the core support and ran the pipe through it. Just over the A/C line for the condenser. That way you run the TIP under the headlight getting better air.

It will never fit there Just the maf is 3.5 inches I'll have a duct from the bumper feed cold air to it I removed the comp housing It looks like I could gain some space there

[400HPA4]

I would trim as much of the light away as possible and make a pretty tight 180 degree sweep to gain room for your intake.

Unfortunately it is going to need to be cast or machined out of solid billet.

[20vturbo]

I would trim as much of the light away as possible and make a pretty tight 180 degree sweep to gain room for your intake.

Unfortunately it is going to need to be cast or machined out of solid billet.

trim the light u mean cut the light the bottom it's no problem It's the adjuster that's in the way If I make my piece I could make a relief for it Once I pass the light I will blend it to 3.5" diam I am thinking carbon fiber what do u think?

[20vturbo]

I would trim as much of the light away as possible and make a pretty tight 180 degree sweep to gain room for your intake.

Unfortunately it is going to need to be cast or machined out of solid billet.

What do you think about triming the comp housing on the intake side?

[400HPA4]

Waste of time...you will need the flange to attach the TIH to.

If I were at work I could draw a TIP for you in AutoCAD, but I am not.

You could build a 180 degree sweep out of fiberglass, or with Carbon Fiber too.

To do this, you can go to your local hobby shop (we have something called Michael's here in America) and buy some shapable foam pieces.

I can draw how it will need to be done roughly with paint for you if you would like to see.

[20vturbo]

Waste of time...you will need the flange to attach the TIH to.

If I were at work I could draw a TIP for you in AutoCAD, but I am not.

You could build a 180 degree sweep out of fiberglass, or with Carbon Fiber too.

To do this, you can go to your local hobby shop (we have something called Michael's here in America) and buy some shapable foam pieces.

I can draw how it will need to be done roughly with paint for you if you would like to see.

Yes I wou8ld like to see Thanks for the help It's about more than an Inch where u slide the hose over I don't need that much for that.....
I am thinging about 90 toward the driver side then another 90 down into the maf and filter Is that what you are talking about I am not sure I understand the 180 deggree you are talking about

[20vturbo]

An interesting ideea is to have the maf and filter where the battery is now and have the battery relocated I am not happy about cutting the firewall though

[20vturbo]

this is my ideea

[mike-2ptzero]

this is my ideea

Using a cobra tube?

[20vturbo]

Using a cobra tube?

It's not gonna work I have to make a custom pipe to fit

[mike-2ptzero]

It's not gonna work I have to make a custom pipe to fit

I dont see how a custom pipe is going to fit if a cobra hose wont unless you plan to cut off most of the turbo inlet and weld the pipe directly to the housing.

[20vturbo]

I intend to shape the intake around the back of the headlight maybe fiberglass or carbon fiber...There is no off the shelv product that will fit there with the head light
I'll have to check the ecodes and see if they allow for more clearance I also think about machining the lip on the comp housing that will give me another 1/2 inch

[JBM]

man that sucks....that manifold blows....

[mike-2ptzero]

man that sucks....that manifold blows....

Well the manifold was designed on a B5 were the head light sits a bit further forward.

[Redgoat]

Mike, what exactly is a cobra hose? Is it a hose that goes flat yet wide??

[gt8]

Mike, what exactly is a cobra hose? Is it a hose that goes flat yet wide??

i think it's a hose used on a 2003/4 Mustang Cobra?

[20vturbo]

it's hose that actually looks like a cobra snake...It allows for a tight fit
you can see it here http://intakehoses.com/Merchant2/mer...gory_Code=CHEW

[20vturbo]

Well the manifold was designed on a B5 were the head light sits a bit further forward.

correct but even a b5 would have problems...there is a dude using the full race mani and he had to chop the light to make it fit.....In the end I'll have it sorted out but it will cost more money and a pain in the ass...Even the b5 hid are a lot smaller then the b6 lights, I thing the b5 headlight has no motors inside, man those b6 lights are huuuuge...I'll have a look today at some eurocodes, I'll try to find out if some early models came whithout motors

[Tgr_Clw]

How about replacing your bi-xenons with single xenon lights? They're smaller.

[20vturbo]

How about replacing your bi-xenons with single xenon lights? They're smaller.

that's what i am doing If u look at the pictures on page 6 u can see it's still tight

[Tgr_Clw]

Ah. Sorry missed that.

[CO AVANT]

Open element!!! hahaha just kidding. That sucks man. Can you take a pic of the assembly from turbo to downpipe? Maybe there is something in that area that can be changed so you can use your current headlights.

[mike-2ptzero]

correct but even a b5 would have problems...there is a dude using the full race mani and he had to chop the light to make it fit.....In the end I'll have it sorted out but it will cost more money and a pain in the ass...Even the b5 hid are a lot smaller then the b6 lights, I thing the b5 headlight has no motors inside, man those b6 lights are huuuuge...I'll have a look today at some eurocodes, I'll try to find out if some early models came whithout motors

I have been running the full-race manifold for about 4 years now without a problem. He might be using a turbo that sits a little bit futher then my GT35r which is something I found while test fitting a few GT30's on the car after full-race built the manifold on my car.

[20vturbo]

the down pipe is another tight fit If you go back there are plenty of picures in the post..There are 2 options so far one is to have the battery relocated and have the filter and maf in there, the con for that is that I'll have to chop the firewall
second is to have the maf and filter sit behind the radiator....Both require a composite pipe to be fabricated

[20vturbo]

he's running it on maf so he can't just slap a filter on

[mike-2ptzero]

he's running it on maf so he can't just slap a filter on

I had it with a maf before I went stand alone. Here is a very old picture with the cobra hose on the GT35r with the full-race manifold.

[20vturbo]

tight as a virgin

[Spinnetti]

when I had the head off and stripped i looked at it and actually the pump pushes air right into the exaust runner after the valve what for I have no iddea...

The SAI system is in part how the A4 got its great emissions rating. The Cat needs to be at a certain temperature to operate properly. Much of the emissions happen during cold start when the cat is not working efficiently. Part of the solution is to move the cat as close as possible to the turbo so it will "light off" faster. The other component is the Secondary Air Injection system that when cold, blows air into the exhaust just like blowing on hot embers starting a campfire.. it makes the cat heat up much quicker. When the cat is up to temp, it shuts off (I think its just on a timer, but similar idea). Removing the SAI system increases cold start emissions, and will likely not pass smog inspection. If you aren't running a cat, there's no reason to have the SAI system either as it wll do nothing.

If you still want to do it, The block off plate is nothing special. With patience, a sander or grinder, a drill and a piece of aluminum you can make your own; I have a shop, so have a few more options though :)

The EGR system stands for "Exhaust Gas Recirculation" and serves several functions, including lowering combustion temperatures and reducing emissions by re-burning a portion of exhaust gas. The down side is it pukes soot all through the intake and makes a nasty mess.

The PCV system vents the crank case. This is important because a portion of the gas blows by the rings and without it pressure builds up in crank case which if not vented would blow oil out of every seal. I read that some race cars actually run a vacuum pump and the reduction in windage (the crank thrashing in the crank case air) makes hp over the draw of the vac pump. I was thinking a one way valve dumping to the down pipe might yield a similar result (assuming a venturi draw from the exhaust).
My car doesn't seem to have much blowby, so I just did the filter thing. A catch can would work too.

[dougyfresh]

Does the cobra intake hat work well? I would think there is a lot of turbulant air with separation zones going into the compressor side of the turbo. In other words, very distorted flow. If you had a nice even flow of intake air I would think the turbo would be more efficient.?.

Then again, there isn't much room in these engine compartments so we're kind of stuck with what we have.

Do you need your high-beam? (I never use mine) I think this might have been suggested but what about hacking a headlight housing apart and mounting the MAF and a small filter in the high-beam spot of the headlight? The come up with a way to seal the remainder of the housing so the main beam and turn signal stay dry. Its a direct shot into the turbo.

[20vturbo]

The SAI system is in part how the A4 got its great emissions rating. The Cat needs to be at a certain temperature to operate properly. Much of the emissions happen during cold start when the cat is not working efficiently. Part of the solution is to move the cat as close as possible to the turbo so it will "light off" faster. The other component is the Secondary Air Injection system that when cold, blows air into the exhaust just like blowing on hot embers starting a campfire.. it makes the cat heat up much quicker. When the cat is up to temp, it shuts off (I think its just on a timer, but similar idea). Removing the SAI system increases cold start emissions, and will likely not pass smog inspection. If you aren't running a cat, there's no reason to have the SAI system either as it wll do nothing.

If you still want to do it, The block off plate is nothing special. With patience, a sander or grinder, a drill and a piece of aluminum you can make your own; I have a shop, so have a few more options though :)

The EGR system stands for "Exhaust Gas Recirculation" and serves several functions, including lowering combustion temperatures and reducing emissions by re-burning a portion of exhaust gas. The down side is it pukes soot all through the intake and makes a nasty mess.

The PCV system vents the crank case. This is important because a portion of the gas blows by the rings and without it pressure builds up in crank case which if not vented would blow oil out of every seal. I read that some race cars actually run a vacuum pump and the reduction in windage (the crank thrashing in the crank case air) makes hp over the draw of the vac pump. I was thinking a one way valve dumping to the down pipe might yield a similar result (assuming a venturi draw from the exhaust).
My car doesn't seem to have much blowby, so I just did the filter thing. A catch can would work too.

thanks for the info I have a catch can installed...I don't have a cat but Cai is still there mainly for the CEL and the nice sound it makes when u shut it off

[20vturbo]

Does the cobra intake hat work well? I would think there is a lot of turbulant air with separation zones going into the compressor side of the turbo. In other words, very distorted flow. If you had a nice even flow of intake air I would think the turbo would be more efficient.?.

Then again, there isn't much room in these engine compartments so we're kind of stuck with what we have.

Do you need your high-beam? (I never use mine) I think this might have been suggested but what about hacking a headlight housing apart and mounting the MAF and a small filter in the high-beam spot of the headlight? The come up with a way to seal the remainder of the housing so the main beam and turn signal stay dry. Its a direct shot into the turbo.

That is a good ideea The maf is 3.5 inches diameter the pipe from the turbo exits in 4 inches not sure the light has enough room for that Another thing is that I can't have the maf too close to the turbo, turbulence will mess the reading

[20vturbo]

The back of the ecodes is the same as the oem light I am choping a light now to make it fit

[roarincheetah]

The back of the ecodes is the same as the oem light I am choping a light now to make it fit

I didn't read through this entire thread, but I read most. Somebody may have asked this, but have you looking into a custum pipe. I think Eric (entertainment72) had one made for his car. Maybe pm him about it.

[CO AVANT]

Eric is just running a modified APR 3+ TIP. There is no way in hell he could jam that in there. It has to be done uber custom style. Is there any other way? ;)

[roarincheetah]

Eric is just running a modified APR 3+ TIP. There is no way in hell he could jam that in there. It has to be done uber custom style. Is there any other way? ;)

Are you sure. I thought erics was a custom, but maybe i'm wrong.

What about a place that makes custom hoses or fittings. Couldn't he just give them the exact dimension and have them fab one for. Yes, yes i know $$$$

[CO AVANT]

Even a plumbing supply store might have what he needs...

I've also purchased stuff from these guys before, they might have something.
http://www.hightempsilicone.com/