My new car!

chickenwafer · Postby **chickenwafer** » Mon Jul 09, 2012 9:14

Thanks guys.

I got in two divided t4 flanges in the mail today from eBay. They were advertised as being 1/2" thick but they're actually 3/8" thick...I was concerned the extra 1/4" of an inch I'd be loosing (two flanges) would be problematic but it looks like the turbo will finally clear the LIM. So tomorrow I plan on dropping off the flanges and my manifold at my welders to get them TIGed on.

Now my only concern is if the charge piping will clear the hood, I'll need to make a new oil drain, and the downpipe BETTER fit or the car will be pushed into traffic lol. I still might need a new v band flange on the downpipe but I'm hoping I can hold off on that.

chickenwafer · Postby **chickenwafer** » Wed Jul 11, 2012 9:14

Flanges are welded on the manifold, did a quick test fit and everything looks good. Haven't tested downpipe fitment yet, and I probably still need a new flange, but I think the v-band clamp will prevent it from leaking. We'll see.

Other good news is while dropping off the manifold with Justin (my welder) we noticed a small amount of light coming through the merge collector so Justin was able to weld that up. Didn't even notice it before and it was definitely a leak so that's also good.

Some pics- I think Justin is pretty good:

Raw manifold:

I then sprayed my manifold with some VHT Flameproof high temp coating (rated to 2000*F). Did a few coats over 2 hours and then cured in my oven in a multi-stage process. First was 30 minutes at 250*F, 30 minute cool down, 30 minutes at 375*F, 30 minute cool off, then finally 30 minutes at 500*F (the paint called for 600*F but my oven doesn't go that high) and I'm letting it cool off in the garage.

These paints usually don't work very well, but I really like the VHT stuff. Works really well and is chemical and oil resistant, plus is reduces heat really well. The finish is also kind of cool, like a powdercoat finish:

Of course the new divided flanges have a different thread pitch so I'll run to Ace tomorrow and grab some studs and lock nuts and then hopefully have this turbo in tomorrow! Maybe I'll even drive it! Holy shit!!

VRx8 · Postby **VRx8** » Wed Jul 11, 2012 9:14

Looks really good. Glad everything is coming together

speedjunkie · Postby **speedjunkie** » Wed Jul 11, 2012 9:14

Are you going to get bolts just long enough to go into the first flange?

chickenwafer · Postby **chickenwafer** » Thu Jul 12, 2012 9:14

I want to use studs, but I may just get bolts. I still have to run that 1/2" thick spacer flange for the turbo to fit properly so I need longer bolts or studs regardless.

chickenwafer · Postby **chickenwafer** » Thu Jul 12, 2012 9:14

Today was frustrating- as usual. Took me the better part of 2 hours just to bolt the turbo to the manifold. Turns out a T4 flange isn't as universal as it should be. The bolt holes in the new divided flanges I had welded on were slightly off from the spacer and even my turbo.

So after struggling to get the bolts threaded in, I ended up having to drill out the gaskets, the spacer, and even the turbine housing holes a little to get it installed. But finally, I got the turbo bolted to the manifold.

Installed the turbo drain with plenty of RTV. Went to lunch to let it cure with the intentions of coming home and slinging this thing in the car. Nope. Because the flange is different, my oil drain is not so freaking close to the manifold flange there is literally no gap to thread on the -10AN fitting!! Son of a @*#^@*#^*@#Y*@^#*(@

So now I need to figure this out, it probably means a new oil drain. Mine is tapped for 1/2" NTP so I can remove the -10AN male fitting and screw in whatever. I'm thinking I may just try a straight or 45* hose barb fitting and see if that works and clamp on some high-temp silicone hose rated for oil. I ran one of those drains on my turbo RX-8 and it worked fine. Easier to install, too.

So, two steps forward, one step back, but I'm hoping Ace will have what I need so I can get this bad thing on the road this weekend.

speedjunkie · Postby **speedjunkie** » Thu Jul 12, 2012 9:14

Sounds like you're having the same problem I had with the oil drain. I hope you don't have to go through what I did lol.

chickenwafer · Postby **chickenwafer** » Sat Jul 14, 2012 9:14

Thanks a late night wrenching sessions last night with Matt (alpha) we got the car 75% back together. Fixed the oil drain situation and got the turbo, manifold, and downpipe installed.

Today when I got home from work I started right away. Finished the downpipe install, installed the wastegate, hooked up the coolant hoses to the turbo, charge pipe, oil feed, and then double checked everything.

She fired up right away, I was real happy with that. Good news, no fluid leaks or anything crazy. Bad news? Of course the downpipe STILL LEAKS at the turbine housing, even with the new v band connection. It's probably as bad as its ever been. While it was running I tightened down the v band clamp even more but the leaks is just too large.

I did notice the downpipe is about 1/2"-3/4" too short, so I'm wondering if extending it might fix this, also adding a flex bellow may work. I just don't know what to do. I've sunk too much into this stupid ### downpipe already so I don't want to just trash it but I'm not sure what options I have.

Rx7store.net has a universal single turbo downpipe made for the manifold I have for $250 bucks. Mine is slightly modified but still, it could work, but it is worth the risk? I guess I could return it if it doesn't fit and I'd just be out shipping cost but I also don't particularly enjoy dealing with rx7store so I don't know.

I really just wish there was a good shop in town I could drop the car off at and have them just fix the downpipe or made a custom downpipe, whatever.

speedjunkie · Postby **speedjunkie** » Sat Jul 14, 2012 9:14

I don't know what it is about exhaust leaks but it seems like everyone has one now. Oscar has one too. Or had one, I can't remember if it's fixed or not.

So your welding guy can't do this for you?

chickenwafer · Postby **chickenwafer** » Sat Jul 14, 2012 9:14

We can weld whatever, the problem is figuring out how the downpipe needs to be re shaped in order to fit correctly. I basically have to try and guess and how it will fit and he welds it and then it ends up not fitting.

It would be better if the entire car could be at his shop so he could fit it to the car. But he's a one man operation in a tiny shop and it's full of "more important" (aka people dropping more money) 8 second drag cars, so he can't take on my car for a simple downpipe.

VRx8 · Postby **VRx8** » Sat Jul 14, 2012 9:14

I think a flex should should do it.

chickenwafer · Postby **chickenwafer** » Sun Jul 15, 2012 9:14

Well I ordered new Garrett 3" v-band flange so it will actually fit my turbo properly, as well as a 2ft long piece of 3" diameter stainless. I removed the v-band clamp off the downpipe and left it bolted to the exhaust system and it looks like the flange needs to be about 1 1/2- 1 3/4" closer to the turbo.

So I think I'll cut a length of 1 1/4" stainless and move the flange closer and see how I do. I need a new plug for my MIG and then I can at least tack it together myself so I'm not getting everything fully TIG'ed up and then finding out it doesn't fit.

Next option is a 3" x 6" flex bellow in the section of the downpipe passing the trans tunnel or by the rear flange. That should give me enough articulation to wrestle it into fitting (I hope).

chickenwafer · Postby **chickenwafer** » Fri Jul 20, 2012 9:14

Sorry, no interesting pictures, but some updates.

Got the Garrett v band flange a 2' section of 3" diameter stainless pipe. I cut off the v band currently on the downpipe and cut a length of 1-1/4" stainless and tacked it to the dp along with the new v band flange.

Test fit and the angle on the v band flange is off. Break the tack welds and reposition. Success! Looks like it will fit good. So I do some better tacks to hold it all in place and do a complete test fit, success again!

So I remove the dp this afternoon and drop it off at Overkill Racecars to get fully TIGed up. Bring it home and the downpipe now fits perfectly! I try not to get too excited because it's hard to tell if a v band flange will leak without testing it. So I fire her up....

No downpipe leak!!!! Wooooooot wooooooot!!!

Buttttttttt......I did hear a very audible exhaust leak from the motor, around the manifold or turbo. Shiiiit. I used a scrap of paper and held it around the joints- the paper will flap from the leaking exhaust pulses. Nothing around the downpipe, tested via the paper method and with my bare hand, no leak. I held the paper around a majority of the t4 turbine flanges and I didn't see it move, but I could get all angles and it was getting very hot by quickly!

Last place to check is the manifold to motor junction itself. I think it's leaking off the rear manifold flange, I will investigate tonight to make sure the gasket is in place and the bolts are tightened.

Good news I am now confident the downpipe ordeal is finished. What a pain. I can now heat wrap it up and install it. Good news is the downpipe is now super easy to install, I can easily do it by myself in less than 4 minutes with the car in the air- two bolts and a v band clamp. Much easier to install now that it's properly fitting haha.

So hopefully I will track down this other exhaust leak and get cracking. I could probably drive it right now as it sits but I hate exhaust leaks haha.

speedjunkie · Postby **speedjunkie** » Sat Jul 21, 2012 9:14

Exhaust leaks build character. Just turn up the music lol.

VRx8 · Postby **VRx8** » Sat Jul 21, 2012 9:14

Very nice! I have a leak from the manifold as well but i think mine is cracked somewhere. Really need to get a new manifold. But i need to hit the lottery first lol

My new car!

Who is online