*this is a long winded writeup so read it all if you plan on asking questions*

well, i am finally boosted. i haven’t had a chance to do a writeup until now as i’ve been pretty busy with moving, etc. there is still a lot of work to do as well, but i’ll explain that as you go thru the pics. i’d like to thank everyone who ever bought a flange off me, i wouldn’t have been able to make this setup possible without hmt’s support.

this is the intake manifold i built last year in preperation for the setup. i’m planning on replacing it with a new “tapered plenum” design at the end of this summer.



this is the turbo i was going to put on the car. TE04H. i got it cheap, cleaned it up and after spending some time on hmt realized it wasn’t going to suit my needs. so i sold it and got a turbonetics t3/t4. i even made a ramhorn for this thing and sold that too.



here is the manifold i made for my new turbo. i made all the flanges... obviously.








i made myself a crossmember to cut down on wheel hop and also to replace the first one i made that i had sold. i had to make some mounts for the civic rad as well and modify the rad to fit too. when i have time, i still need to modify this cm so that i can incorporate the front engine mount again.







here is the downpipe. i wanted to incorporate the wg into the dp to save a bit on room. it ended up turning out ok, but it is a little crooked and i will have to modify it to mate it to the cat a bit better. i also intend to get rid of the cat and run a flex pipe section there instead.














now modified:




one of my biggest problems to overcome was fitting the intercooler. the core is 26x12x3. i wanted to use a 22x9x3 but bmc was out of that size. i made my own end tanks to reduce piping. as you can see i had to make some changes in order to fit it. i didn’t want to modify the bumper either.

some mocking...


had to cut the front a bit to make room.


here is the new front frame piece that i made. it is removable and has to be so i can get the intercooler in and out.


mock up with the intercooler core:


the reason i went with a custom intercooler was so that i could minimize the amount of charge piping. here is how it came together:

first design the endtanks:


had my brother make some forms out of mdf.


make a template out of paper.


trace it onto some 16 guage aluminum.


cut it out.


start forming.


weld one side.


trace the hole on the other side and cut it out, weld the pipe to it and the weld it to the core.


put that sucker in! no modification to the bumper or bumper rebar was made.




i made the end tanks a little on the narrow side. i have another core i may make another intercooler with and widen the end tanks out a bit so the pipes aren’t so tight against the rad on one side and the oil cooler on the other.

the next obstacle to overcome was how the hell do i connect these two together?


solution: one special “ghetto bend”. this thing took forever to make because after each piece i added i was checking to make sure i was going in the right direction to make it fit.




my hm bov:







setup fab work all completed.




more recent pics:




here is the setup breakdown:

turbonetics t3/t4 bought off hmt
2.5” dp (3” will replace it eventually)
short runner manifold
tial knockoff wg bought off hmt
dsm 450’s w/ resistor pack (to be replaced by 550’s from tunertoys soon)
VAFC bought off stealthmode
zietronix WBO2
26x12x3 intercooler core (bmc)
2.75” charge piping (ebay)
triangle engineering 10g aluminum fuel cell (local shop)
msd inline fuel pump (local shop)

coming soon:
msd btm
sheet aluminum intake manifold
lsd sitting on the shelf

 

i like writeups like this

 

nice work

 

nice fab . very impressed.

so when you tuning it?

 

Holy crap. That's a great job you're doing there.

 

damn........your a pretty good fabricator! good stuff!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by non-VTEC &raquo;</TD></TR><TR><TD CLASS="quote">damn........your a pretty good fabricator! good stuff!</TD></TR></TABLE>

Exactly, that is damn nice welds to be doing it yourself. Looking great

 

Compliments on a great, "built it myself setup"

looks good

 

Jesus thats alot of fab work! Did you make the car too?

 

mad props fabbed almost everything

 

Thats some great looking work man, I just finished up a setup as well were i fabed alot of it. Feels good to see the finish product.

I do have to ask though is this a street driven car, and if so did you reinstalled your main front bumper?

 

thats impressive. Nice work

 

wow man... lots and lots of fab work !!! super good job...!!! have you dynoed the car yet??

 

awesome job with everything
it all looks great
props for doing it solo

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Muckman &raquo;</TD></TR><TR><TD CLASS="quote">Jesus thats alot of fab work! Did you make the car too?</TD></TR></TABLE>
lol, no kidding!

Nice freaking work! I wish I had the time and experience to do things like that. Much props for you!!!!

 

Very Nice Work

 

nice job man

 

maybe u already answered this but can you please explain your oling systme to the turbo is that an oil cooler and where do all of the lines go any pictures of that or just tell us how you have that setup! thanks man looks sick!!!

 

very nice job on the fabbing. i dig the home made bov too, it looks nice.

keep up the good work man, get some numbers on the bad boy

 

That's awesome, I wish I could fab my own stuff.

 

thanks for the compliments guys. i've had the car for almost 9 years and worked on this setup just in the past year.

front bumper: stock, i wanted it so i did not have to modify the rebar at all. yes, it is daily driven when the weather is nice.

oil setup: oil cooler is infront of the turbo. the remote oil filter is behind the driver's side head light. i believe you can see it in one of the pics. i made the adapter for the filter and the spin on adapter that replaces the filter on the back of the block from solid billet aluminum last year but it was in a different location because i wasn't boosted at the time.

tuning and dyno: i am sending out the ecu next week so i can get setup with uberdata and burn my own chips. i have a set of 550's that are going to be going in the car then along with an adjustable fpr. when i make my new intake mani i'll dyno the car. right now i still have to install a blitz power meter i-d that i bought in japan. i can't read japanese though so i have to figure out the wiring on my own.

 

damn that **** is hot, I like the HM BOV

 

im loving the setup man. Very nice and for lots of DIY!

 

nice job! how thick is the metal you used for the end tanks?

 

This makes me happy in my pants..........