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.

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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
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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...

Re: S2000 turbo kit
 

who are you and why arent we related

Re: S2000 turbo kit
 

so sick. is that a corolla in the background i see. red 2tone.

Re: S2000 turbo kit
 

Cool. Any thoughts on if mounting the turbo so rigidly could actually cause cracking rather than prevent it?

I've always seen bracing as a bit of a guessing game, where I try to brace enough to help dampen vibration and take some load off of the header, but still try to allow for some expansion/contraction due to heating/cooling. But it's exactly that- I'm, just guessing.

Also, I assume the plan is to have a wastegate pipe come off of that elbow after the collector somewhere?

Re: S2000 turbo kit
 

Yes I did have that concern but after talking to a dragster manifold builder, he said it should be ok.

Yes the wastegate is coming off the elbow.

Thanks for all the kind words.

Re: S2000 turbo kit
 

Welcome to homemadeturbo. That's better than porn right there.

Re: S2000 turbo kit
 

I just cummed........ only a little

Re: S2000 turbo kit
 

+1

Hawt.

Re: S2000 turbo kit
 

Awesome work!

Wanna sell that F20c you just have laying around?

Re: S2000 turbo kit
 

RHD?

Re: S2000 turbo kit
 

my exact thoughts

Re: S2000 turbo kit
 

NIIIICE...

Re: S2000 turbo kit
 

Though that boosted F20C into the 86 that was in the backround. Screw that S2000.

Re: S2000 turbo kit
 

brilliant work alan.

Re: S2000 turbo kit
 

VTECLUDE or wWEIR
GUYS
Wont those couplers on the intercooler will blow off, I had them too, 4ply right, weld a 45 onto the endtanks and get a 45' coupler. Will eliminate the boost shock the to edge of it. They will blow a hole.

Other than that. THATS SO ------- AWESOME
What happened to the finished pictures to the h22 topmount in a civic manifold and a non mocked up DP.
You still have my attemtion on that.
EVILLE140 you observing this. Your making my next front mount ya know.

Re: S2000 turbo kit
 

well i just came. BAM grammar on yo ass!


spectacular work, the back purging is a nice touch as well, that little bit extra is really worth it.

this pipe fitting company that i used to work with did that ---- on all the process piping they would put in at the brewery.

they had a multiple carts with 18 tanks of argon just for backpurging because there was so much piping, but the welds were so ------- nice inside and out.

Re: S2000 turbo kit
 

They won't blow off if the pipe is bead rolled. The coupler itself will expand though and start to seperate internally. We had a 4 ply 90 on a Mustang with an F1R at 24 psi and the coupler was destoyed after the second pass.

Re: S2000 turbo kit
 

Mine was bead rolled and the fucker blew right at the 90' mark.

Just suggesting a helping hand to the cause.

It's still a sweeeeet setup
Wish I would of bought a S2k instead of a K series POS CRV

Re: S2000 turbo kit
 

Yeah, I said blow off not blow up.

Re: S2000 turbo kit
 

Good job. I always felt the s2000 should have come with a turbo anyway-- they handle awesome and are fun to drive, but kind of ----- stock. It was fun hitting the 9k rev limiter though. Boost ftmfw.

Re: S2000 turbo kit
 

Pretty much done now.

Attachment 12652
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Re: S2000 turbo kit
 

awum work !
I agree on the 2000 needing a turbo its a great car needing a little more (a lot more) push..
noob question
i noticed you havent welded the tubes to the flange on the inside. Will you be doing that or
is there a reason not to ?

Re: S2000 turbo kit
 

I've done that already. Will get a pic of it when I get a chance.

Re: S2000 turbo kit
 

Good purge, clean materials. really good heat*travel speed = some very bright, clean welds.

Re: S2000 turbo kit
 

is it illegal to hump a header in US?? ;D

Re: S2000 turbo kit
 

Don't know how I missed this.
I wish you were my friend.
---- looks tits

Re: S2000 turbo kit
 

Thanks for your compliments. It really means a lot to me. If I could weld half as good as you I'd be happy. Still not as consistent as I would like but I've never been taught how to weld. been Tig welding for 10 months now and think I'm still getting better.

Re: S2000 turbo kit
 

i just wanted to know what kind of rig you are using welder wise? and your weld rod

Re: S2000 turbo kit
 

The welder is a british made Inverter Fusion 200hf. Goes up to 200 amps. I used 308L 1.2mm rod.

Re: S2000 turbo kit
 

Thanks. Na just keep welding and try to always improve and you always get better. I still have lots of things I work on when I get the chance to do it.
Tell you the key to it. Understand you're human and you can totally ---- up in the least way. Like. I'll be going on making as absolutely perfect of a weld I can make & something stupid will happen. Hand twitch or whatever. Mother fucker but what can you do about it, eh.
Consistency just comes with doing it. If you keep welding you get there!
Anyways, anything you lack in consistency you seem to make up for the correct welding decisions and clear welds. By decisions I mean I like your weld sizes. (I think (tho not a real problem) many guys tend to undersize their welds slightly.) I like they even tho it's not 100% you're correctly deciding to weave your cover passes instead of trying to make one GIGANTIC cover pass, or wash a big pass down & thin it out.

---- weave passes kicked my ass for a LONG time! I mean yeah I could always do the little ones, but I worked on that ---- on and off for MONTHS before I got the big ones down.

Re: S2000 turbo kit
 

:y

I likes