Something I have been working on in my spare time over the last two years. Things really began to get started about a year ago with building up the engine/trans. Got it running naturally aspirated this spring and tuned it over the summer getting it just right before boosting it.

Turbo system fabrication began about 4-5 months ago. I'm no welder for sure and doing this project has given me the utmost respect for real fabricators. All tubing is 304SS and I used a FirePower 120 MIG machine using Tri-Mix gas & 308L wire. Some welds came out great, others look like ****, but they are holding up fine ... I have been running boost for about 3-4 weeks now with limited miles ... maybe 250-300 miles at most.

Turbo is a Precision SC-61. Up pipe tubing is 2.5" and down-pipe/exhaust (no cat) is 3".

To follow the entire buildup, here is a link to the thread. The thread index in the first post is updated periodically, so keep an eye on it. I have a dyno appointment today at 2PM EST, so dyno results will be posted there as well ... right now, I'm just killing time for the next 45 minutes.

Pre-Boost Dyno:



Fabrication underway:

































Had to lower the Wastegate for a little more clearance on the waterpump tubes:





Did some bracing:





Now for the Cold Side piping:






























Modified by FastCougar at 1:26 PM 11/13/2007

 

not bad, thats some serious home fabricating..... for doing it yourself.

 

Thanks!

I'm sustaining 12.5 psi without a problem and will dyno her at 14 & 16 psi as well ... hoping for 450+hp & 400+tq ... heading to the dyno in 25 minutes

 

Close but no cigar ... couldn't get past 11 psi

Very pleased with the numbers considering ... I just need to figure out this damn AEM TruBoost EBC and all will be good.

391.9 hp @ 6750 RPM, 374.2 tq @ 4250 RPM, boost @ 11 psi.

 

nice job
that looks like a tight fit

what welder was used for those pipes ?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by EFbomb &raquo;</TD></TR><TR><TD CLASS="quote">nice job
that looks like a tight fit

what welder was used for those pipes ?</TD></TR></TABLE>

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by FastCougar &raquo;</TD></TR><TR><TD CLASS="quote">All tubing is 304SS and I used a FirePower 120 MIG machine using Tri-Mix gas & 308L wire. Some welds came out great, others look like ****, but they are holding up fine ...</TD></TR></TABLE>

 

You should have used some flex pipes in the (2) down pipes. It's going to crack.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by FastCougar &raquo;</TD></TR><TR><TD CLASS="quote">Close but no cigar ... couldn't get past 11 psi

Very pleased with the numbers considering ... I just need to figure out this damn AEM TruBoost EBC and all will be good.

391.9 hp @ 6750 RPM, 374.2 tq @ 4250 RPM, boost @ 11 psi.</TD></TR></TABLE>

wow thats some nice power for 11psi, torque monster . what do you use to tune those things?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by SMSP &raquo;</TD></TR><TR><TD CLASS="quote">You should have used some flex pipes in the (2) down pipes. It's going to crack.</TD></TR></TABLE>





That'a all one pipe ... from turbine housing to vband clamp.

 

i think hes talking about the crossover pipes from the manifolds. though thats not as much of a concern as they move with the motor. id be more concerned about how far away from the turbo that flex pipe is on the downpipe. i would have placed one on the first section of straight on the downpipe in the engine bay.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by FastCougar &raquo;</TD></TR><TR><TD CLASS="quote">

That'a all one pipe ... from turbine housing to vband clamp.</TD></TR></TABLE>

I know.

Here's your bigger problem.



It's fixed at 3 points.

Stainless steel expands about 50% more than mild steel.

You have 2 unequal length tubes, one will grow more than the other but the ends are fixed therefore you are generating even more stresses. Plus I suspect that there was no back purging of the welds.

 

I will keep an eye on the welds for the up-pipe, as you are correct, I did not back-purge. However, if they do crack, I have 2 2" flex pipes waiting to go in. Thanks for the input!

 

This is a V6 right?

I am trying to figure out how I am going to help a friend do a Single turbo on a mustang. I can't see how you run the pipes when you have 2 manifolds.

 

Nice work man!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by CBURKE &raquo;</TD></TR><TR><TD CLASS="quote">This is a V6 right?

I am trying to figure out how I am going to help a friend do a Single turbo on a mustang. I can't see how you run the pipes when you have 2 manifolds.</TD></TR></TABLE>

look at the post above yours, you have to make an "uppipe" that joins the two exhaust manifolds to a turbo flange...

 

i was like why the f is he boostin a cougar...then saw the 374wtq number at 11psi and thought....hrmmmm.....notttt too baddd

good job on the home fab work looks great for a first timer

pratice makes perfect

 

edit: i didnt realize it was a built motor.....**** u put a lot of time and money into it......too bad the car is fuglyyyy

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by m R g S r &raquo;</TD></TR><TR><TD CLASS="quote">edit: i didnt realize it was a built motor.....**** u put a lot of time and money into it......too bad the car is fuglyyyy </TD></TR></TABLE>Stock motors have been proven to 400 whp ... my plan is to push well beyond that, so I went with forged rods & pistons.

 

Pretty cool, curious to see what it runs on the strip.

I had planned to do a similar setup on my V6 Camry, built motor and all but backed out to persue another project.

 

That's wicked. Good job guy.

 

I have been doing a turbo KL-ZE swap .. thanks for the modivation

 

Feels good to have ~380 ft lbs in an ugly looking car wooping up on cool looking hondas


&lt;-- 394whp/387ft lb 99 Dodge Neon (it weighs 2200lbs )

torque bitches! nice job

 

Nice man im going to show my buddies this. They swap the 3.0L motors into there contours

 

Chances are if they are a CEG or FCO member, they know who I am ... I have been around both groups for quite awhile. If they don't know about CEG or FCO, they should get involved with the Contour scene. Oddly enough, this project build actually involved me rolling a 98 SVT Contour. If you really give a ****, here is what happened:

http://www.contour.org/ubbthre...art=1

Like all my "documentation" threads, this one is rather long as well. In a nutshell, the idea was to buy an already boosted Cougar or Contour and swap out the drivelines so I could be that much closer to my track setup Cougar. The ONLY turbo kit that was sold at the time was $6,000 and way over-priced in my opinion. The plan backfired when I did a boneheaded thing and bought a car sight unseen. Turbo kit was crap, engine was toast, yada yada yada. So, I try to make the best of the situation and drop a 3L into the car and get it ready for selling. In testing the car, I swerve to miss a deer and roll the car ... totalled it ... the same day I registered it.

It all turned out for the best I guess ... the car was a totally cursed POS and rolling it was the best ending for it. The engine/trans that I swapped in ran great, so I bought the car back and sold the engine/trans and took a minimal loss on the entire fiasco.


Modified by FastCougar at 1:38 AM 11/20/2007

 

holy cripes thats wicked! crazy what Dave(smsp) knows just by looking at something like that lol great job