Here's something I've been working on with my friend.

1 problem with USDM parts, and getting them to fit on UKDM/JDM cars is the obvious LHD/RHD differences.
This difference was a problem with the Full-Race ram horn turbo kit for the s2000 that the customer purchased for his vehicle.
The brake booster, steering column and abs unit fouled the ram horn manifold on his JDM s2000, which meant the turbo kit took a back seat in his closet until a RHD kit was made. 1.5 years later, he couldn't wait no more, and so went in search of a custom turbo kit. most places booked him in, and kept on rebooking him, as they were swamped with work. Annoyed by that fact, he asked if we (angel-works) could turbo his car.
We agreed to take on the project, and collaborated with Solid-fabrications. And in 2 days, we have designed and mocked up a sidewinder bottom mount manifold, 3 inch downpipe and exhaust, and boost piping. There are a few things left to do, (wg, bov, weld everything together) but the major components are in place.



Apologise for the fone camera pics, will be getting better pics taken once the manifold is complete.

The original design was to go with a sidewinder top mount setup, ala inline pro/love-fab, but then that wouldnt allow a 3 inch dp, as they dont have the steering column to contend with. Being a bottom mount, angling the turbo at 45degrees, or there about wasnt gonna be easy, especially trying to turn the 3 inch downpipe around the vtec solenoid and oil filter.

heres a few pics of the kit being made.

making a temporary jig to hold the turbo where we want it.


20 hours later and the manifold, dp, exh system, boost piping is done. i did take pics of the process inbetween, but thought i'd load the best pics.



heres some pics of the turbo kit on a mock engine we had lying around.







we ran out of straight sch10, and had to make do just to get the manifold complete, but the long section on no4 will be gettin replaced.


heres pics of the turbo brace/manifold support




another triangular gusset will be added for further support.

the collector clears the bonnet/hood with about 10mm to spare. an oil filter relocator will be needed with this kit.
best of all, a 4 inch d/p will fit aswell, but the customer specified a 3 inch dp and exh.
the turbo hangs 7mm from the chassis cross beam, and theres lots of space for the wastegate.
best of all, there are only 2 boost pipes, suprisingly, you can manoeuvre the boost pipes into place, even though they are such long weird shape pieces.

material used:
sch10 3mm for the manifold
cnc milled 12mm stainless turbo and manifold flange
2.5 inch stainless hot side boost piping
2.5-3 inch stainless cone and 3inch cold side boost piping
3 inch stainless dp and exhaust.
6mm stainless turbo brace.

all TIG welded, and manifold will be back purged.

Pic of the JIG







Root pass



Flange welded up

 

Downpipe flange




Welding the elbow onto the collector. Back purged of course.





Welding the inside of the of the T3 flange.



One runner welded up. Thought it would be best to start with runner 3 first.



Second runner welded up.



Third runner welded up.






Sorry for the bad quality pics. Just have a phone camera on me.

Thanks for looking.

 

good quality work looks amazing. One thing that I can c that would bother me is the brace that attaches to the block blocks the tct service plug. Tct's go bad pretty often on this car and it would **** me off to take all that **** of just to change it. None the less awesome build.

 

Looks nice, cant wait to see what it looks like once your done.

 

Quality work.

Could you please PM where your shop is? I've just recently moved to London (about 2-3 months ago) and am in search of a shop that does some quality work for when I get a project car going. Also have tons of questions about MOT (obviously) LOL.

 

Your work looks very good! You might wanna try posting this in our fabrication forum as well.

 

Nice work! Looks a lot like the AFI manifold...


What are you shooting for power-wise?

John

 

That's sick.

 

very nice set up! what are your hp goal?

 

well, the owner is gonna run it on a stock engine, so i guess 400hp or so.

because its a gt35r on a stock engine, im more interested in the spool up rather than out right power. i dont see the kit being a restriction.

 

nice work... good power i hope to see.... welds are amazing!

 

nice work can't wait to see the power it makes.

 

Might want to get ahold of Mase for the tuning. He just custom built a RHD GT35r for a guy in London. Made 600+rwhp, stock engine (head and internals), on 110 octane. I think mid-500's could be had no problem, provided the right tuning.

John

 

That turbo is overkill for 400HP, should have went with a GT30.

 

If that's the case ... wrong turbo choice.

 

make 600whp on stock motor.

 

im no master welder or anything, whats up with the tinfoil and the little tubing?

 

Quality work but if the hp goals are 400 you should have definitely gone with a GT30

 

no doubt the owner should have went with a gt30r. he's looking to straight swap anyone with a new gt30r for his new gt35r.

 

mase is tuning it.
he is over in 2-3 weeks time, so thats our deadline.

 

Pretty much done.

 

Pretty much done.

 

update?

 

UPDATE!!!

Got a phone call that Mase was gonna be over in the UK this weekend, so i was asked to finish the turbo kit and fit it in time for Mase to tune it.

With 6 days till Mase was tuning, it was a flat out dash to get everything done, order parts, test fit, fit, refit, order more parts. What a crazy week!!!
We made it to the rolling road at about 6.40pm. About an hour after everyone had their cars tuned and gone home.

Thanks to the guys at DS automotives for hanging around and being great hosts, Phil for organising mase’s trip , and a Good job from Mase.

So heres some pic and graphs for all to stare at.





400whp @ 13psi!!!!!!


Oh and can someone add a caption to this pic???


I’m thinking, vtec goes like this…. bbrrrrrrrrrrNNNAAAAAHHHHHH

 

noice! can you weld one of those for me for a LHD?