S2000 turbo kit
 

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

making a temporary jig to hold the turbo where we want it.
https://img.photobucket.com/albums/v...g/DSC00632.jpg

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.
https://img.photobucket.com/albums/v...g/DSC00652.jpg
https://img.photobucket.com/albums/v...g/DSC00653.jpg

heres some pics of the turbo kit on a mock engine we had lying around.
https://img.photobucket.com/albums/v...g/DSC00655.jpg
https://img.photobucket.com/albums/v...g/DSC00662.jpg
https://img.photobucket.com/albums/v...g/DSC00660.jpg
https://img.photobucket.com/albums/v...g/DSC00659.jpg
https://img.photobucket.com/albums/v...g/DSC00661.jpg


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.
https://img.photobucket.com/albums/v...g/DSC00657.jpg

heres pics of the turbo brace/manifold support
https://img.photobucket.com/albums/v...g/DSC00663.jpg
https://img.photobucket.com/albums/v...g/DSC00665.jpg
https://img.photobucket.com/albums/v...g/DSC00664.jpg

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

https://img.photobucket.com/albums/v.../IMAGE_200.jpg
https://img.photobucket.com/albums/v.../IMAGE_203.jpg

https://img.photobucket.com/albums/v.../IMAGE_204.jpg
https://img.photobucket.com/albums/v.../IMAGE_213.jpg

Root pass
https://img.photobucket.com/albums/v.../IMAGE_219.jpg
https://img.photobucket.com/albums/v.../IMAGE_220.jpg

Flange welded up
https://img.photobucket.com/albums/v.../IMAGE_214.jpg

Downpipe flange
https://img.photobucket.com/albums/v.../IMAGE_208.jpg
https://img.photobucket.com/albums/v.../IMAGE_210.jpg


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

Attachment 12762
Attachment 12763
Attachment 12764

Welding the inside of the of the T3 flange.

Attachment 12765

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

Attachment 12766

Second runner welded up.

Attachment 12767

Third runner welded up.

Attachment 12768
Attachment 12769
Attachment 12770
Attachment 12771

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

Thanks for looking.

Re: S2000 turbo kit
 

nice phone cam.
Must be nice having a spare F20c laying around.

Re: S2000 turbo kit
 

Awesome welds. Nice work, sir.

Re: S2000 turbo kit
 

pardon my ignorance, what is the purpose of the hose running in to the pipes you are welding

Re: S2000 turbo kit
 

I believe it for back purging with argon gas to sheild the weld from oxydizing when the weld is cooling down.

Re: S2000 turbo kit
 

bad ass!

Re: S2000 turbo kit
 

That is correct. Also keeps the weld strong and smooth inside.

Thanks for the comments.

Re: S2000 turbo kit
 

Good ----.

Re: S2000 turbo kit
 

good ----!

Re: S2000 turbo kit
 

thanks for the info...