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Discussion Starter #22
Well nothing too exciting to report still. I have been busy as hell finishing the garage, and getting our house ready for a party this weekend. I did however order up a bunch more material and pieces. I should have everything to build the intercooler piping except the intercooler (which is on backorder). I have all of the material to build my exhaust, but will probably need a couple v-bands so I can section it. Anyway, here are a couple pics.

Half stainless, half aluminum 4" V-band. I have two stainless steel 90's to come out of the turbo and get me to about the firewall, then it will be aluminum from there to the bumper. The other three pieces are 3" aluminum clamshell clamps for the intercooler piping.


Detail of the 4" v-band


And one of the clamshell clamps pulled apart.


I also got two boxes of piping as well. Those have a single stainless steel 4" 90, ten 3" aluminum 90's, six 4" aluminum 90's, two 4" aluminum 45's, two 2' long aluminum straight sections, a 3" silicone coupler, and a 3" to 3.5" silicone adapter with T-Bolt clamps. I am really hoping to start fabrication next weekend now that I should be done with all of these other projects. My pile of parts/material is starting to take up too much space!


Sean
 

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Nice build so far.
 

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Very cool build! I work at a Lexus dealer. I have two LS400's. One with 115k miles. A guy in the shop is building Turbo 2jz GSLSE right now. He has a sc400 also.


Ray
 

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Discussion Starter #26
Finally time for a bit of an update! After busting our asses on Friday night, the garage is now 99% done. All that really means for non OCD people is that I have more than 2 outlets (a LOT more) and don't need to drag extension cords all over! Let me back up a second, I needed to get the steering rack out of the car since it was wore out and I got a replacement for it. I also wanted to take the motor out to make taking the rack out easier, and so I could do some things with it on the stand. Thursday night I got under the car and pulled the trans.



Pretty easy to do with nothing really connected at all. Friday the car and the bike went outside while my buddy and I did the massive amount of electrical work in the garage. Saturday got mostly eaten up cleaning the garage from the previous nights thrashing. In the evening I got the car pulled back into the garage and was able to get back to work on it.



I let the snow melt off and dry up a bit before getting to work pulling the motor. Not terribly hard (again, nothing to disconnect or move), but kind of a pain in the ass since I have to come at it from the side.


So one of the first things I wanted to try, was see about fitting AC. I don't think I would run it this year, but if I could build with it in mind it would make things easy down the road. I grabbed a bracket and a junk compressor from a buddy so I could mock it up. He also had this manifold laying around, so I took that as well.




It is clearly a tight fit, but I think I could make it work. It pretty much kills running a 4" downpipe on the passenger side though, so I grabbed a piece of tubing to see what it looked like on the driver side.




Again, very tight but I should be able to make that work if I need to. I still haven't decided if I am going to mess with it or not, but its good to know about options. Next up was getting the front accessory drive all installed.

All laid out on the bench (minus the water pump since I forgot where I put it!)




Unfortunately I have the wrong tensioner, and I clearly still need parts (balancer, thermostat housing, alternator, etc.) but I can move forward with fabrication for now. Once that was done I pulled out the old rack.




Then I got the new poly bushing installed in the new rack


Then got it put in for now.


I am going to change the "EVO component", intermediate shaft, and outer tierods but its in the car so I can fabricate around it for now and keep it out of my way.

Then I got busy organizing all of my material so I could clear the space under my bench.

Pile of tubing!


Ahhhh thats better


At that point I was going to call it a night, but I decided to dive in and try and get something done. So I busted out the big boy grinder


Then I hacked off the end of the driver side manifold


Unfortunately, that was where I had to end it. Its been so long since I have welded, the batteries in the hood were dead! I am going to stop and get some on my way home today, and I am also waiting on some welding supplies. It was great to FINALLY be working on the car again! Like I said I am still unsure on the whole AC deal, but I think for now I am going to cut up that manifold and see whats up. I will also be putting the motor back in the car as soon as I get my new steering parts (that is a whole story on its own). Thats all I have for now, thanks as always for following along!

Sean
 

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Discussion Starter #27
What a weekend! Friday was all yard work and Saturday was supposed to be all car. While it mostly was, I had to help the wife with some Christmas decorations a few times. Before we get into Saturday, lets go back a bit in the week when I got some welding materials!

It has been a few years since I have welded (something that is sure to be obvious going forward) so I needed to stock up on pretty much everything. I ordered up a bunch of filler rod, some tungsten, and a fancy new gas lens cup.




That is a #16 GLS Fab gas lens. I have never used anything like it before, but wanted to give it a shot. I also picked up a tungsten grinder from eastwood to help get a nice grind on my electrodes.

So Saturday morning I went out in the garage and was messing around with stuff when I knocked the TIG torch off of my bench!!! Luckily the gas lens survived with no problem. The brand new tungsten didn't do so well, but that isn't a big deal since I have a few of them. I go to take it out, and it all comes out fine, sharpen up a new one and when I went to put it back together it was a no go. Long story short the collett wouldn't go into the back cap pretty much at all. I tried some others I had for different size tungsten and no dice. Turns out that every single welding supply place was closed until Monday!!!

After calling a dozen places to be sure they were not open, I thought of McMaster Carr, and sure enough they had them in stock. I ordered up a new back cap and some colletts and headed to Elmhurst to pick them up. I have ordered from them plenty of times, but never went there or even noticed where it was. It took me FOREVER to find where the will call window was. I even called and was still lost after that. Anyway, parts in hand I went back home and found that none of the colletts fit the new back cap at all. I was able to make something happen with the old cap and a new collett, but the day was off to a rough start.

When I got home, my new saw was waiting for me though!


After I figured out that I could make up at least 1 TIG torch (in case I had to run out again before they closed) I got to work assembling the new band saw.


First test cut


It took longer to assemble than I expected, but so far it works great. I should probably dial it in a bit more, but I wanted to get to work!

Started with the most basic thing ever, tacking the V-band flange onto the driver side manifold.


I then started trying to get some basic idea for how to get it pointing in a better direction.


After that was good enough to be able to go back in the car, I went over to the passenger side to stare at the AC for a bit again. I cut the flange off of whatever manifold that was and tried to see how I could get around the compressor.


Not much to look at I know. Next I needed to get the engine and trans back in the car so I could place the turbo. This is no easy task by myself, and made a little more difficult having to get the car so high up for the trans to go underneath on the trans jack. Nothing a chain and a cherry picker cant fix.




I also cut the ears off the trans to make my life a lot easier getting the lower bolts in. So I got the car up, got the trans under it, lowered the car back down and picked the motor. That was an interesting dance of bringing the cherry picker in from the side(ish), holding my hood up higher, and maneuvering the motor around everything in the bay. It was mostly successful, but I did break a clip for the fuel lines.



After that feat, I got the trans bolted to the motor, and tried to get the mounts fully set into place. As it sits right now, only 3 of the 4 motor mount bolts are in their homes. I tried for a while to muscle the motor around to line that last one up but so far its a no go.

I figured it was close enough to start looking at things. Right away I pretty much decided that the AC was not gonna be worth the hassle. I don't think I would be able to get a 4" downpipe through the bay with it in place for starters. I ended up pulling it all off, and went back to the truck manifold on that side. After that I threw the radiator back in to see whats what.


That did not look good.... I grabbed the turbo, and


No dice. That is resting on the water pump and the fan. Just for shits I tried seeing how it worked on an angle behind the passenger headlight


I could probably make that work ,but its not my first choice. By this time it was pretty late on Saturday, and I had been up since pretty early, so I called it a night.

Now I am trying to decide how I want to go forward. For starters the front accessory drive I have is utilizing the truck spacing. That moves everything out about 1/2". That is not helping, but I also don't think that moving it back in alone will give me the room I need. Remember this car will be seeing street miles so I need to keep things like the fans cool as well. I can start chopping out the radiator supports which is something I am not against doing at all, but that means a new radiator and fans. Oh well, I will figure something out soon. It would have been nice if it fit like I planned, but that's life.

Sorry for the more wordy post today. Thanks for following along!


Sean
 

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Discussion Starter #28
Last night I was out in the garage for a bit trying to figure out a game plan for the SC. As you saw in the last post my plans for the turbo placement didn't really work out well. So I spent some time experimenting with different locations and clocking etc. For now I am thinking that this setup should work.




(Bad pic)




I still need to work out a few details before I commit to it. The down pipe will clear between the motor and the shock tower up high, but I don't think its a clear shot down in the back of the motor to get under the car. I need to look at that closer for sure. I also want to put the headlight back in to see what everything looks like with it installed. I am not 100% sold with this position, but it seems like it should work OK. Pretty much anything else would mean moving the radiator and the accessories. I am fine with doing both of those things, but we will see.


Sean
 

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Discussion Starter #30

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Discussion Starter #31
So I headed back out to the garage tonight just to check some things. First up, I was messing with the placement AGAIN. I tried moving the radiator forward, moving the water pump back (no spacers), and so on. I could probably make it work with some finagling, but then I checked the down pipe routing...




While (like everything) I could make that work, I didn't like it. Not with the truck manifolds anyway, and if I was changing those I have almost every option open. After that I got back to looking at the down pipe down the back of the motor. I still need to remove the absolutely massive ABS module, but looking good.




That pretty much cements the turbo placement behind the passenger headlight like I had yesterday. Now that I have a target, may as well start fabricating!!! First up, cut down some tubing.


Then it was just a matter of marking it up and giving it a couple good tack welds. Sounds easy, should be easy...was not easy. Part of it is that I have not welded in so long. Part of it was the helmet flashing me constantly. Part of it is probably also the new gas lens, and my inexperience with it. Long story short I was having a hell of time tacking it with the TIG so I got pissed and got out the MIG. Forgot to check that the regulator was actually letting gas out (it wasn't). Then when I got that figured out it ran out of wire. No joke, I did one tack went to the other side and there was nothing. I ended up doing the second tack with the TIG, but still struggled. Nobody cares about any of that, but I needed to vent :)

Anyway, because of all that BS I only got one tube tacked in.




Not much to look at, but its going toward the turbo :D The sway bar is hanging there, so just ignore it. Looks like I need to order some straight tubing so I have less seams. I need to decide how I am going to clock the exhaust housing. That is going to dictate a few things for sure. Maybe I will look at that more later this week or this weekend.

That's all for now, thanks for following along!


Sean
 

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Discussion Starter #32
Time for a Sunday evening update!

We will start back on Friday where I got a little bit done after work. I started by welding the v-bands to the manifolds 100%

This is the passenger manifold, which was a bit rougher than the driver side.


The welding went OK. I started with the GLS lens, and ended up swapping back to the old style nozzle part way though the driver side. I will get back to the lens when I start welding the tubing. Anyway, here is a pic of the passenger side welded up. Not my finest work, but oh well.


Hard to tell, but both are all done in this pic


That was pretty much all I got done Friday night.

Saturday I didn't really get much done. I straightened up the garage a bit, then decided to get the turbo sitting down a bit more. So after running to Home Depot to get right size hole saw, I popped a hole in the car




I think the only other thing I got done was cutting off the sway bar. The bolts on the end links striped out, so out came the angle grinder :)

Sunday I got back out to the garage for a few hours and had at it. I started by welding a tube to the passenger v-band.


After staring at everything for a while I decided to just dive on in and cut up one of the 90's.




The saw did awesome! I thought of using two 90's so I could keep the tubing lower across the engine bay, but I don't really need that space for anything. Also cutting one 90 meant I still have one left for later if I need it.

After I got it cut, I tacked up one side to the driver tubing, along with a straight section I had cut off something else earlier.


Here is a shot showing the other 45 sitting on top to give you an idea of how it will be routed.




The general idea is that the T4 flange will be adapted to 3" tubing. I am going to do a 45 degree 3" tubing cut down as much as possible and the two sides will merge into that.

Since I don't have the flange yet, and need to order up the 3" tubing as well as some other things, that was about all I could really get done on the crossover. So I decided to start messing with the down pipe. I started by cutting a 4" 90 in half since I needed a 45. Unfortunately the saw couldn't handle doing the 4" the same way I did the 2.5" No big deal, just changed to to vertical and did it by hand. Not as clean that way, but it worked. Then I chopped off the straight section from one of the pieces.


Then I marked and cut that piece down, and then tacked everything together.




That's all for this week. I need to pull out that monstrous ABS deal. I also need to get more material on its way so I can have everything for next weekend. Its been kind of slow going, but at least progress is being made.

That's all I got for this week, thanks as always for following along!

Sean
 

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Discussion Starter #33
Small update time! Last weekend I was pretty busy, and I was still waiting on parts. I was also hung up on needing to get the turbo mounted before I could really do anything else. I ended up ordering a Maven oil drain mount after talking with them a bit. It is a little expensive, but it is SUPER nice, came packaged very well, and the customer support has been fantastic! Super high quality part for sure, and also probably the best way to support the turbo.


I have some molly tubing coming for that today, and tomorrow morning I am going to grab my buddies bender. Hopefully I can make something work, and look decent with that.

Yesterday I finally got my new 3" to T4 flange! I didn't grab any pics of it before I promptly cut and tacked on the 3" 45 bend.


That's all for now. Not much, but those two pieces were holding me up. I have to get some hardware for both of them so everything can get bolted together. Then I can keep running the tubing up to the turbo. I also ordered up an intercooler, so hopefully that show up soonish and I can start on cold side piping. I am still undecided on doing any kind of flex in the crossover. I probably should but not sure what kind. Anyway, I should have some more done Sunday so stay tuned.


Sean
 

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Discussion Starter #35
How does the Maven turbo mount work? Do you weld it to a pedestal that is attached to the frame?

Andrew
It is machined in the ends for tubing. This is the small frame version, so I believe its set up for 7/8" and 1" OD tubing. So the tubing is welded to the car or chassis, and the mount. Then the mount is bolted to the drain for the turbo, and your fitting goes into the mount. I should have more pics of it all this weekend.

Its not exactly a new idea, but I think they are the first to mass produce a machined option. I looked into making my own and into having one machined. Since I don't already have any material around I would need to buy literally everything and it started to add up. I ended up sending them a message with some questions, and after talking to them a bit I was sold. Mostly on the great interaction I had with them since I already knew the product was good. From the packaging alone (which I wish I would have taken pics of) it is very clear that they take pride in their product which is made in the US. I am glad I pulled the trigger on it for sure.


Sean
 

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Discussion Starter #37

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Sweet build.

Whats the overall plans? Tire? Suspension? etc
 

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Discussion Starter #39
Sweet build.

Whats the overall plans? Tire? Suspension? etc
Thanks!

Plans are constantly "evolving" but general idea is fast street car. Stock suspension, drag radial. I want to run Drag Week with it right now, so that is the main focus. I would love to start chopping it up and getting nutty, but I am trying not to so that it can be on the road in the summer. More or less, part of me wants it like OEM but with 1,000 WHP, and another part of me wants a X275 car. We will see where it lands :)


Sean
 

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Discussion Starter #40
Got a small, boring update for you guys. My intercooloer showed up yesterday! I went with a Treadstone 1245 air to air. Nothing too fancy, but should get the job done.



Should end up somewhere in this ballpark




I think I have come up with good solutions to all of the little issues I have been running into lately. Unfortunately with Christmas coming I am super busy, and don't really know when I will be able to get back out to the garage. I may have a little time today after work, so maybe I can get some some tacked up and show some progress.

Anyway, I am happy to have another piece of the puzzle in my hands. I need to brush up on my aluminum welding before I start trying to weld up the clam shell clamps. I always liked welding aluminum, so hopefully it comes back pretty easy. Thats all for now!


Sean
 
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