Speed, are you going to uyse one turbo to start with, then bring the second in when there is enough exhaust gas flow???

what do you think wiull be the upper limiots of that setup??

thanks Chris.

 

Bryan,

buy a spec 5 cluch and teh plasma!!!

 

Caleb - If you remember my 30th, it will be mounted just like that. It's just an inch thicker and with two fans this time which is why I have to build a cross member rather than modifying the existing one. I've got the front of the car apart so I'm going to get it mounted up this week. I've got to swing over and pick up the welding gasses today and I'll get started this evening. I'll post up some pics..

Chris - yes, exhaust will be diverted to one turbo until some threshold occurs where exhaust will be sent to both turbos. I'm not sure what you mean by upper limits. If you mean by maximum horsepower supported, that just depends on what turbochargers you choose.

Tiago - I just scored a McLeod twin with an aluminum flywheel! I think the plasma might be on it's way in the next day or so too.

btw - are you still running a 10 bolt in your t/a?

 

no, but I never broke it, I got a 12 bolt now....

 

Hope mine does that well. I just put in a new T2r about six months ago but I know when it comes time to crank that boost a bit, I'll feel more comfortable with a 12 bolt.

 

Ok, so I got a little more done. I had the week off and intended to get the intercooler mounted and the battery relocated. However, I installed new lights in the kitchen and bathrooms as well as a few other honey-dos. I don't blame it all on that as I spent quite a bit of time working on the controller code and I think it's time to call it beta ready. Now the fabrication...

I went ahead and fabricated a new front cross member and mounted the fans. It's been quite a while since I welded aluminum and I forgot just how hard it is to weld a small thin piece of aluminum to a large thick (relatively) piece. So the welds look like **** but you can't see them anyway. They are solid (ask me how I know) but not the nice row of stacked coins.

Anyway, here are some pics...

Intercooler with fans mounted on tabs. I used three tabs instead of four to save weight...



Kidding, I left the 4th tabs off to clear for the original rear mounting scheme I ended up not using. In the pic below you can see I relocated the hood support to the back of the radiator support mount. This cleared the hood support out of the way so I could snug the IC up against the radiator support. To either side, you can see where I drilled two holes in the radiator support for the rear IC mounts. This turned out to be much cleaner that building a bracket but I had to chamfer the mounts and used beveled washers since the radiator support is about 30* off from the IC mounts. Probably overly complicated but cutting off the excess material from the mounts created the washers and the chamfer in the process.



Here is the semi-complete front cross member. It will also provide a mounting point for the front IC mounts as well. A little pipe insulation will also provide some support for the facia.





Left to do is to weld some angle for the lower cross member bolts since the lower beam sits too high to redrill holes in the frame tabs. Then prime and paint the cross member and clearance the facia and the IC portion of this build will be done! Too bad it only gets harder from here......

 

subscribing

 

Oh yeah, I forgot to post this. This new mod probably will produce the best results per net dollar spent then any other mod you will ever buy for anything. ever....

 

Nice work! Looks like you've got some good tunes to go along with the project as well. Johnny Cash is the man

 

You have to take everything over the top don't you Bryan

I'll have to check in on this little project of yours often

BTW- what car are you doing this on?

 

Yeah Cash is the man. Along with that jewel case is Disturbed, Pink Floyd, and a Karen White case my wife lovingly but unknowingly donated to the IC positioning cause.


Chad - Coming from The Chad, over the top is quite a complement! Gotta have a little fun every now and then. I'm putting this on an 01 SS I picked up this summer. My neighbor had it but they needed an SUV and I needed something with a little better mileage. So we swapped the Trailblazer for the SS and I bought her a Lexus IS. Can't beat a little horse trading!

How is the painting hobby going? You are quite the man with that airbrush I hear! Very cool

 

looking good Bryan.... lets get some turbo mounting pics

 

looking very nice there speed! need some turbo pics though!!

Chris.

 

Turbo pics are coming soon gentlemen! Got to get the peripherals done first. So I worked a little late tonight and got her IC surgery done!

Here is the cross member painted and mounted.



Starting to go back together a little bit..



Little shot underneith to see how it all lays.



Pic of how the new cross member mounts to the tabs on the frame horns



Through the hole in the facia



All put back together. Never know by looking at it there is 1200 cubic inches of IC hiding in there.



I tested the fans and they really do pull a lot of air through that IC. On my last flat mount IC, you could feel the inlet and feel it being much warmer than then outlet felt ambient. I need to get one of those laser thermometers so I can check it out of curiosity.

 

wow that loos sooo clean! be nice to see just how effective the layflat idea is. and i take it the fans are pull fans??

stupid idea for the track, but be really nice to use on the road, a set of intercooler sprays spraying ice cold water from a boot mounted tank. just to help get temps down even further!

also you have to remeber that the fans are needed to help keep the front end planted at higher speeds!

thanks Chris.

 

Thanks! Yes, they are pullers. It is more efficient to pull air than to push it. I'll come up with some way to check inlet and outlet temps and let everyone know how it does. The fans are rated at 900 cfm each so I'm guessing we can get ~1500 through the IC. The airflow basicly follows the stock path so I'm not expecting any problems or changes there.

Next I think I need to get the board made for the controller. I'm going to probably just use perf board to test and make some nice PCBs later.

Also some quite hit items will be the battery relocation and fuel system upgrade. I've got some 60 lb/hr injectors and I think I am going to go with twin intanks and a better flowing fuel filter.

 

Just a quick update here. Haven't done much in the line of fabrication but I got in some supporting parts on order or here. Picked up a McLeod street twin with aluminum flywheel and sending off the order for a new 9in from Driveline Solutions today. Spent a bit of time talking with Scott on the phone yesterday for the rear and he was happy to talk with me for a bit and answer questions. Since this car is a street car first and it will see some time turning corners as well as running in a straight line, we decided to go with a 9 inch/tru-trac.

I got a good portion of the devel board built for the controller unit and just spent some time laying under the car deciding on pipe routing and such. Since we get all four seasons here (as evidenced by the 5 inches of sleet sitting on my driveway and the 112* summer we just had), I don't want to give up anything as far as creature comforts for this car. It is a daily driver. Although I hate logs, I decided for this first version, I will build a log for the passenger side and build a crossover pipe for the drivers side. Then I will bring the exhaust forward to where I had planned to locate the turbos in the battery tray area. I had to bring the exhaust together somewhere for sequential operation anyway so I thought that would work.

This will allow me to retain all of the accessories including AC in their original positions. The down pipe(s) will have to go under the k-member unless I can figure out a way above it. I seen in another thread, Ping King had pulled it off so I'm curious how that worked. I ran under the k-member on a couple of other kits and it wasn't bad. As with everything, there are tradeoffs.

I'm also going to fab up a new torque arm and strut tower brace when I swap rearends. Hopefully the weather will warm up so it becomes bearable to work in.

 

I didnt read your whole thread i just pretty much read the details and looked at the pics so correct me if im wrong...

Are you going to get some more Radiator fans and put them back on or are you just gonna leave it like that???

also...what brand intercooler is that??? the one i have front mounted on mine is 32" X 12" X 4"

 

The radiator fans are stock and remain in their stock locations. The radiator and AC condenser also remain in their stock locations. The fans in the picture are mounted on the top side of the intercooler and pull air up through the intercooler. The air flow follows the same path as it does stock.

The intercooler is an ebay unit. Where did you find a 32x14x4?

 

ebay too lol...what company did you get it from?? it sounds like you got it from the same one i did cause he was the only guy i found on there that handled 4" wide intercoolers...everything else was 3"....i must say when i got this thing i couldnt believe how massive it really was lol....deff. made a huge improvement over the one i was replacing it with

your fan idea is a pretty cool setup. I have never seen anyone mount fans like that on a intercooler and still be able to keep under hood temps down...nice work