MawneeC5

I've begun tinkering with it so its time to start a build thread.

Fair warning, this will not be a speedy build. While I have ordered many of the parts already, I'm still undecided on some and will deal with them when I get to that point. I daily drive the car and will be working on the setup in sections to avoid a lengthy downtime. I also live in Florida and it is far too hot for me to go out and knock this out in a week in this august heat . My intent is to do the final install and tune this winter. I will update this thread as I make progress and have something to show

Ok, so on to the build and goals. My current car is an 03 Z06. I have already installed a 228 cam and Spec 3+ clutch. The turbo is a Turbonetics TC76 Hurricane "Vanessa" 68mm turbine .96 ar. I went with both oil and liquid cooled for longevity. I will be building a top mount similar to the Cerra/Hinson setup. My goal is 575rwTQ, I don't care where the HP ends up. I want a quick spooling, responsive, fun to drive to work car.

So lets start

I'll be building the main manifold out of schedule 10 weld Els and pipe. 1.5" for the primaries and 2.5" for the main log. Mind you schedule 10 is oversized, so the 2.5" actually has a 2.875"OD and 2.635id.

I have an old head on my bench for test fitting and building on. Here I am guessing at the turbo flange location:



In order to dial in the turbo location I made my "Handy Dandy adjustable Turbo Flange locator!"



And here is me fiddling with the location. I am going to have to put it in just the right spot to clear the hood and still get the manifold over the water pump outlets. This will be easier once my smaller coolant reservoir arrives.



Thanks for reading

gotjuice?

Should make for a nice daily driver. Good luck on the build.
Leave the inlet filter off, So you can get rid of the rodent. I see damage in the last picture.

JDS99

NICE!! Looking forward to the build.

Gotta love the start of a build thread! It doesn't feel like it's been that long since I had a spare head viced to my bench for manifold work

You sure you don't want to put another one of those on the other side? It will spool by 4k

MawneeC5

Tonights project, Round peg, square hole. The catch here is there is no room for a proper transition and bend. Even this way it barely clears the coolant lines coming out of the water pump.

MawneeC5

Thanks.

I don't have any rodents. Though I think I see what you see in the pic. Its actually the injector harness over the vacuum line, not a chunk missing. though admittedly my engine is kinda dirty. Gotta love that florida sand/dust....

venomws7

Good luck with the build man I did a custom setup with ST80 with similer turbo location with very low timing , Rich fuel and only 11psi made 670rwhp 625rwtq I'm now going with something bigger

Are you going to use the stock driver header? What size downpipe?
Your goal should be very easy to get.

HolyShiznit

Honest question: If 575 wtq was all you wanted and you were dead set on that type of set-up....why not just order a Hinson hot pipe kit and save you a lot of time/effort/etc? The Hinson set-up especially with a turbo like yours (small exhaust side) would spool easily and hit your numbers.

MawneeC5

I will be putting the stock manifold back on the drivers side. 3" downpipe.

My entire kit will cost barely more than what Hinson wants just for the hotside pipes. I'm putting in the time and effort to save the money.
Also because I NEED a project. I get bored when I'm not tinkering on something. I take far more pride in saying "I built this" rather than "I bought this"

FourG63 97GST

Awesome, I'm parts gathering at the moment. I like the Hinson kit too but I want a 3.5" downpipe like Venom ST80 setup. been shopping aggressively. I'm currently at $1440 in parts (precision billet 67, treadstone intercooler, precision 46mm wastegate, generic 50mm Bov, eBay intercooler piping "kit") Only thing left that I need is the hotside piping and fabbing and whatever misc that pops up

FourG63 97GST

Btw that header flange you have there, where did you get and what's the I.D of the exhaust port.

MawneeC5

Nice! Sounds like you are roughly where I'm at. I have most everything but the cold side ordered. I really considered the Treadstone IC, but even that is a tad pricey. My two other options are an Evo X IC which is side in top out and the top mount Rx7 one that is top in top out.


Ebay 3/8 thick 1.820" ports stainless. Its made by Dynatech. The lip of the 1.5" Weld Els sort of fit into it like a ball so I can rotate them around a bit and still have a full seal.

MawneeC5

Doing some work tonight:
-Laying down the radiator
-Tapping the oil pan for an oil drain
-Installing oil feed
-Installing modified stock thermostat(shimmed to roughly 180)
-Installing and plumbing a smaller coolant reservoir to clear up space for the turbo




Look at all the junk in the radiator!


Smaller reservoir

FourG63 97GST

What welder do you have?

MawneeC5

At the moment just a Harbor freight 170amp mig(with gas) in my garage, my old 70 amp for tacking died last week. I have access to a nicer miller unit at work. My main log manifold I'll just be tacking together and taking to be professionally Tigged with the proper backpurge. The crossover, downpipe and midpipe I'll probably weld up myself.

Zeus-of-Boost

very interesting. subscribed. keep up the good work man

MawneeC5

I wish I had this much room for a turbo...



Drain installed.


NOW its a proper project...


Drain line clears the power steering cooler and subframe perfectly. I'll probably still wrap another hose around it just incase.


Moved lower brackets forward 6"


Made this much room up top.

MawneeC5

All done. Please excuse the coolant res mount and all the coolant lines. This is temporary as my turbo is liquid cooled and I'll have to redo it then. I also ran out of energy and did not install the oil feed. Though that doesn't look too hard to get at later. For now I just stuck a huge bolt in the drain with a clamp to keep it sealed.

I also installed a stock thermostat I shimmed to lower the temp(about .100"). It works perfectly. Before my car would idle between 193-196, now it stays 180-183

FourG63 97GST

interesting, I'm eyeing this carefully, I'm starting to stray and look at fender TT setups.
I want to see your manifold and downpipe, Downpipe clearance is my only concern right now. I want 3.5"

MawneeC5

Manifold and downpipe will be a little while. I had some power tools stolen from my garage a couple years back and didn't until today realize they got my chop saw

3.5" downpipe will be tough. I've been measuring and plotting my manifold design and its going to be tight getting a 3" downpipe down there. Part of the problem is that the 2.5" schedule 10 piping I'm using for my manifold is almost 3" od so its taking up more space than the thinner stuff Cerra/Hinson used. I will find a way though

c5vette211

Found your build. Im right there with you. I am coming in less than $2500 for my build and I can say I built it.