AEB 254267 My build thread

[Rodgman15]

I've got some rough measurements, but nothing concrete, Im pretty sure the turbo will be in a decent spot. As far as wastegate plumbing, routed back into exhaust or screamer tube I have no preference, whatever I can make work. Kinda wish the wastegate outlet was facing the passenger side instead of the rear.

I'd appreciate some measurements if you've got all that stuff apart, I'll take any help I can get!

[Avant Nate]

Since the head lies at an angle,
I just put a small t-square against the head exhaust ports and measured in inches from the top row of exhaust studs for spacing for the rail.
For measuring from the engine support, I measured square out from between the two middle exhaust studs and and then down.

For hood height, it is roughly 4 inches from top edge of the head to the hood blanket at the center.

In your mock up, I think the turbo is too far from the head, and is going to really hard to make the turn at the firewall. It is approximately 8 inches from the #4 top bolt position to the firewall.

[Rodgman15]

Wow, dude, thank you so much for that that's awesome! So I wonder if I tip the flange upwards and angle the rear inwards a bit. I can always pie cut the downpipe too.

On another note some of the buds and I got out for a nice cruise today!

[Avant Nate]

Also, given that the clearance between the firewall and the back of the head is 8 inches, I would aim the centerline of the turbo exhaust 4 inches out from the back of the head. Some manifold designs require a crazy bend to avoid the firewall.

So far I think my favorite placement is the Agtronic manifold, albeit v-band.
http://www.audizine.com/forum/showth...fold-GB-Feeler!

Think along the lines of Poopie http://www.audizine.com/forum/showth...76-T3-Manifold

If you're really gung ho, i think you should be trying to make the runners equal length. And twin scroll.

[Rodgman15]

Poopie did a really good job on that, I like how he was able to mock it up, looks like the best way to do it. I should just break down and buy a JDL manifold. Money isn't an issue, I just really wanna fabricate my own manifold lol. Equal length would be optimal, and twin scroll is out of the question being the turbo hotside isn't twin scroll.

[Rodgman15]

Trying another revision. Thanks to nate's measurements I think this so should work. Clears the wastegate on the back side as well.

[Rodgman15]

If the height is wrong, easy fix on the belt sander. Been too busy to get anything done lately.

[Rodgman15]

Lucked out, looks like everything will fit. Downpipe is gonna be tricky, but doable.

[Rodgman15]

Welded solid.





Pretty proud of this piece lol

[Bordom]

I like. Did you go with a thicker guage steel to help prevent cracking? Those welds are mighty beefy

Everything graciously mispelled by Android

[Rodgman15]

I believe it was schedule 30, the manifold itself weighs like 30 pounds lol, It came in a kit from Treadstone. And to answer your question, yes. The Holset going on it is roughly 30 pounds as well, so strength was key. Used 3/32 rod where the pipes met the flange for a thicker weld.

[Rodgman15]

Talk about a super lame build thread.

Toasted a South Bend stage 3 clutch on a stock turbo/stock displacement . Not even 1500 miles out of the piece of shit. Southbend admitted they made an error on their end, and instead of replacing my clutch they obviously fucked up, they're giving me their stage 5 setup for $500. Not happy at all being that I have to replace all the bolts and the throwout bearing as well (i'm not taking a single chance). I'll be ordering that Thursday and hopefully putting it in the next weekend on a hoist.

Until then, here's a picture of my finished manifold that took 213098572958 years to build.

20160422_162901.jpg

[The Overclocker]

Nice build man ! I have a very similar build my self ! Cool shit


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[Rodgman15]

Thanks! At the rate i'm moving with this turd it should be around 2019 by the time I get it going

[Rodgman15]

$1300 later...



Starting in on it tomorrow, back on the road Saturday morning.

[redline380]

That's going to drive awesome in traffic.

[Rodgman15]

That's going to drive awesome in traffic.

LOL I know right. Gotta have something that can keep up with my HX35, haven't had much luck with "lighter duty" clutches.

[Avant Nate]

LOL I know right. Gotta have something that can keep up with my HX35, haven't had much luck with "lighter duty" clutches.

Wait, I thought you could just use a RA4 Stage 2 with a HX35./s

[Rodgman15]

Wait, I thought you could just use a RA4 Stage 2 with a HX35./s

APPARENTLY, according to some other threads here on AZ, I don't need:

1) Rods
2) Adequate fueling setup
3) An incredible clutch

[Rodgman15]

Little update, was supposed to have this in this weekend, but... Work. Hoping next weekend it'll be rocking and rolling, so I can drag some ass on silly Honda kids.

All mocked up for now so I could see what the whole apparatus looked like, pretty fucking proud of the way it all came together. Just need another piece for the exhaust and a few stainless lines and I should be golden.

[demonmk2]

$1300 later...



Starting in on it tomorrow, back on the road Saturday morning.

you could have gone with a south bend dxd stage 4, 8 puck that could more than handle your power goals.
when that 4 puck goes ( it won't last long at all for a dd ) you might be able to get a 8 puck disc to swap in.

[Rodgman15]

you could have gone with a south bend dxd stage 4, 8 puck that could more than handle your power goals.
when that 4 puck goes ( it won't last long at all for a did ) you might be able to get a 8 puck disc to swap in.

That is the South Bend "stage 4", biggest thing they make for this platform. i love the clutch, talk about positive engagement.

[demonmk2]

what made you get a 4 puck?

be very careful when engaging 3rd gear..

[Rodgman15]

what made you get a 4 puck?

be very careful when engaging 3rd gear..

Lots of misinformation from manufacturers to make the story short lol. I've been using a Southbend setup for a few years now and decided to give this a whirl to hold up to my HX35. It's next to impossible to "bang" gears with this clutch. I'm sure in the heat of the moment at the track or something i'll let it dig, but on the street i've been letting the gears do the work, easing through the shifts.

[demonmk2]

you could get a flow control valve. jhm sales them it could help with your shift engagement
for the setup you have. when I was doing my setup I talked to mike hood. guy really knows his stuff and was very helpful with my questions.

[Rodgman15]

you could get a flow control valve. jhm sales them it could help with your shift engagement
for the setup you have. when I was doing my setup I talked to mike hood. guy really knows his stuff and was very helpful with my questions.

There's no doubt about that, Mike Hood sure does know his shit, unfortunately, I talked to him after already ordering my new clutch setup. Luckily, I really like what i've got now, but I know there'll be another new one in the next year or so. I'm not too worried about rough shifts, I just have to take it somewhat easy no matter what as I don't want to have to replace transmissions every 2 weeks. I'll let the big turbo do the work and ease through gears.

[Rodgman15]

Some exhaust work, a few fittings to tighten, wastegate to plumb in, and a tune to modify for E85 and upload. Hopefully I can fire it up around noon tomorrow! I'll get some more pictures of the inlet setup/intercooler piping tomorrow.

[Rodgman15]

[tar]

Congrats this looks very well put together and props on the manifold and downpipe. Make sure to post a start up video for us

[Rodgman15]

Thank you kind sir! The down pipe was a bear, but I pitch wood when I see how glorious it fits lol. Had it running yesterday, just need a few hours on the laptop dialing things in.

[Rodgman15]

Spent all day fighting a small oil leak and switching over to e85. Got a few good pulls out of the deal at 15 psi, but a little more work is needed on the fuel and timing tables, then i'll take a video!

[Rodgman15]

Here's a crappy little clip I took on my way to work this morning (in Mexico). Timing is still a hint goofy, and fuel isn't where it needs to be, but it pulls good at 15psi.

[Rodgman15]

So I smoked a 2.8 trans, go figure. Got my old 1.8t trans at the shop so I'll slap that in to get me by. Whoda thunk it eh? Lol

[Rodgman15]

Back from the dead.

So, I'm a complete moron and forgot to put my hood pins back in and voila!



Broke the windshield, mangled the carbon fiber hood. Serves me right. Threw the new glass in last night.





Car runs like an absolutely raped ape. Beating up on my roommate and a buddy with a supra while I can. They're putting down good numbers, but they have tons of headroom left. I feel like if I try to run more boost I'm going to lift the head right off the block or something crazy. Might as well try it out.

I'll try to get a new video of it running at 30psi, it's a monster for such a small engine.

[Rodgman15]

Here's a 40ish to 100ish to give you an idea of how she's running. It's got a bit if a miss, or my trans is falling apart, but it's pulling pretty good. Tough to film and drive at the same time so I didn't run it all the way through it's rpm range. Still have some intercooler pipes that like to blow apart as well, so it still needs a few things here and there.

[Rodgman15]

Felt ambitious this morning, got my 2 step working. Sorry no flames, wastegate isn't routed back into the exhaust yet :(



This is my custom 3" downpipe from the turbo to about halfway back, where it vbands into the 2.75" Milltek system. Resonator removed, muffler only. It's too loud, I'll be setting up the resonator and resonator delete with vband ends so I can swap them in and out when I feel it's necessary.

[Dan[FN]6262]

..

[Rodgman15]

Dead thread. I did some things. Full respray, swapped pre facelift body parts for facelift panels. Brilliant black. Only thing left to paint is the engine bay, which I'll do next time I yank the engine. A few before and after pics, from the day I picked up the car to today. Should be getting to the dyno soon, still waiting for the air to warm up.

Had to redo my PCV/vent system, too many leaks and too many blown gaskets and seals, setup on a scavenger system now which works much better. Polished intake installed as well. Will be redoing the entire fuel system in a few weeks.

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[Rodgman15]

Oh ya, and I got it to shoot flames lol
https://cloud.tapatalk.com/s/58eabe55...90480128_n.mp4


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[Rodgman15]

Welded some fittings onto a stock fuel rail, welded the holes closed, gearing up to put stainless lines all the way back to the tank. Much more cost effective than buying a rail (I'm cheap).

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