Success and setbacks

First the success... The wife and child spent a few days back home and despite having to proctor the ACT test I found time to build the exhaust bridge from the manifold to the turbo and then from the turbo out. I haven't connected the muffler or anything just worked the pipe down underneath so that I can later. I will use my old muffler but as I am going from 1 1/2 to a new 2 1/4 system more bottom side work has to be done. I refuse to hack into the old system until this is proven, part of my "this is likely to fail" back up plan. I grabbed some fittings from Napa bolted on the pipe and got myself ready to hear the sweet sweet whine of success... but there was that failure I spoke of.



From the manifold to the turbo. Kept the size small (1 3/4) to maintain velocity.





Mounting plate isn't perfect, the turbo inlet is an oval and the pipe is round. I did the best I could, ok that isn't true. I did the best I could quickly.


Set in place with the compressor side removed. The tightest part is between the steering shaft and the oil drain but it works. I can cut and weld that small pipe later if need be. It makes me nervous because the shaft's u joints should be replaced with some custom ones. Better be small custom joints.


The spiral cable is the speedometer, the wires and gas line are easy to relocate. The other tight spot is down on the master cylinder. I have break lines passing within 3/4 of the down pipe about 18" downstream from the turbo. I know this set up will not generate the kind of temps a high pressure setup would but I still think that is too close.

The setback:
All of the fittings on this and most turbochargers are banjo fittings, metric banjo fittings. When I was taking it off the car I knew how important those fittings were. I have distinct memories of carefully lining them up so the copper washers would not get lost. I need three, I remember grabbing six. The three I needed plus some spares just in case. I am sure you can see where this is going. I have no idea where my three went. No problem, I have the extras, and I could see them sitting on the top tray of the tool box. Crisis averted so I get to work. Cut to the end of the day, it is time to start hooking up the lines. The moment I have been waiting for...

Turns out the three 'spares' I grabbed are all the same size (14 1.5 I know now) the fittings on the turbo are three separate sizes. Screwed. When I went to the local Napa they laughed and said the best they could do was a new turbo. I can not even tell you how heart broken I was. I had been looking forward to that start for so long. At the time I didn't even know what sizes to look for and spent a fruitless hours searching online before admitting defeat. Dad sent some metric taps back with the wife so I was able to determine hole and thread and if he can no locate them (unlikely) he will pick up some bolts, lathe them out and tap them for good old American fittings. With luck I should have one or the other by this weekend. Barring that now that I know the sizes I could try searching for them again or simply drill out the housing and tap them American pipe and be done with it.