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Made only half of the story. Now we must make slots for O2 sensors. Mill the surface of the pairing. Make the view. I also want to say that I bought the other turbocharger. It is more suitable for my project. But one must make a remote wastegate valve.
http://s59.radikal.ru/i165/1207/60/2cc23d4bbed1.jpg
http://s51.radikal.ru/i133/1207/b9/e66d55d56653.jpg
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On the new turbocharger no valve wastegate. Therefore it is necessary to make external valve. I bought it. Bore diameter of 44 mm. Only after that you can continue the manufacture of exhaust manifold. http://i074.radikal.ru/1207/6a/1dfee3e50110.jpg
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The next step. Part of the warm up up to 300 C. And dipped in a special acid solution. This gives protection of metal from corrosion and dark in color.
http://s15.radikal.ru/i189/1207/90/6059835ef9e2.jpg
http://s45.radikal.ru/i110/1207/68/741ec2beb700.jpg
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Now you can mill the surface. And put the laser its logo. Then you can place on EBay. Heh-heh-heh.
http://s018.radikal.ru/i503/1207/a2/d283adb7075f.jpg
Laser logo.
http://s09.radikal.ru/i182/1207/73/402ea77c4254.jpg
Now the exhaust manifold is ready. You can continue.
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Soon it will earn in full force. 01082012036 - YouTube
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Now the intake tract ready. I haven't done a beautiful appearance. I will do it later. Now the task is to write a program control of the motor.
http://s019.radikal.ru/i613/1208/6d/d197f2ef26e0.jpg
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killed a whole day to set up. The first attempt failed. Now tell. I wrote a program for the engine. Reflash ECU. Started the engine, everything works. Went to test the car. Immediately, from the first meters of the car very powerfully accelerated. I was very happy. I think we should try to maximum acceleration. Press the pedal to the end. The car breaks off with a squeal of tires. Pressure on the instrument jumps to 14 psi. Then there was a Bang and the engine stalls. Thought that exploded something. Open the hood. Here's what I see. Exploding plastic cover.
http://i038.radikal.ru/1208/9e/5b3a28a15b7f.jpg
I took off the cover. Installed the plug on a rubber tube. And went back again to test the car. Again all is well. The attempt to maximum acceleration. Again something popped and the engine stalls. Open the hood, now I see it. Burst rubber tube.
http://s019.radikal.ru/i611/1208/8f/c5b7666de58d.jpg
That's much worse. I had to go to tow up to my repair shop.
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I wanted to maximize the use of OEM parts. However, the safety relief valve was not adjusted and I made a high pressure.
I never give up before the problems. I made metal intake tract. Today again I will adjust the engine, now everything works.
http://s11.radikal.ru/i183/1208/83/d04385d9e9cf.jpg
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The program for the control of the turbo written. Now you need to make the final look and torque stand. However, not all so is simple. I don't like how that is done at the moment. First of all you should install the intercooler. This will reduce the temperature of the air and increase density. I bought a cooler, but it is still on the way to me. The second task, to make the intake tract before the turbocharger. The thing is that I measured the temperature of the air in the stock air filter and when Dryflow filter.
Result: stock 56C (132F), dryflow 71C (159F) .This is an occasion to think, those who establish themselves dryflow filter.
So I decided to make housing for the stock filter.
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The stock filter housing consists of two parts. I need to rotate the housing by 90 degrees. I left that part in which the MAF sensor. The second part is to be made.
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