21 alternator.jpg
22 hits | 68.5 KB | Posted: 9/17/24
Alternator mount bolted down with the correct new bolts. Tensioner is tight to the bracket as well. It is all the way at the end of its travel though so I'll need to drill a new hole to turn it down some.
(Posted in: 2024 Big Turbo)

21 pipe.jpg
19 hits | 68.98 KB | Posted: 9/17/24
Cardboard template and pipe cut. Seems to be pretty close. The bend slipped a tad and the last cut wasn't square so it will need a trim. But almost done cutting stainless pipe for this project.
(Posted in: 2024 Big Turbo)

22 mock up.jpg
21 hits | 66.39 KB | Posted: 9/18/24
Crossover pipe tacked into the major bends. Makes it easier to get angles right when you are mocking it up in the car. Sitting next to the cardboard sections which were pretty accurate.
(Posted in: 2024 Big Turbo)

22 tacked.jpg
26 hits | 72.44 KB | Posted: 9/18/24
In the car and tacked in place except for the flex section. I mentioned it before but having something like the flex pipe where the fit is a little loose makes the final fitting a little easier. The pipe clears everything down there by at least an in...
(Posted in: 2024 Big Turbo)

23 tacked.jpg
21 hits | 65.19 KB | Posted: 9/20/24
Crossover pipe all tack welded and prepped to final weld.
(Posted in: 2024 Big Turbo)

23 crossover welded.jpg
19 hits | 81.83 KB | Posted: 9/20/24
Crossover pipe fully welded and in the car.
(Posted in: 2024 Big Turbo)

24 drivers side.jpg
14 hits | 76.87 KB | Posted: 9/26/24
Final pipe driver's side
(Posted in: 2024 Big Turbo)

24 passenger side.jpg
13 hits | 77.11 KB | Posted: 9/26/24
Final pipe passenger side
(Posted in: 2024 Big Turbo)

24 crossover steering.jpg
12 hits | 51.38 KB | Posted: 9/26/24
Final crossover pipe with clearance to steering.
(Posted in: 2024 Big Turbo)

24 down pipe.jpg
15 hits | 58.52 KB | Posted: 9/26/24
Final downpipe
(Posted in: 2024 Big Turbo)

24 all pipe.jpg
15 hits | 101.11 KB | Posted: 9/26/24
Final pipe all before coating
(Posted in: 2024 Big Turbo)

25 turbo.jpg
0 hits | 49.08 KB | Posted: 10/8/24
Starting on the cold side. Cut the huge v band flange off the turbo outlet and welding on an o-ring fitting. Much slimmer and gives you some misalignment.
(Posted in: 2024 Big Turbo)

26 flanges.jpg
0 hits | 59.95 KB | Posted: 10/9/24
Comparison of the turbo outlet flange sizes. The Evil Energy flange is much smaller. Much easier to assemble and disassemble too.
(Posted in: 2024 Big Turbo)

26 welded housing.jpg
0 hits | 51.31 KB | Posted: 10/9/24
Flange welded on. No too bad. A lot of junk in the cast that kept bubbling up and welding 1/4" cast to 16 gauge 6061 was tricky. It won't leak or fall off, so that'll work.
(Posted in: 2024 Big Turbo)

26 turbo outlet.jpg
0 hits | 52.8 KB | Posted: 10/9/24
Flange assembled on the turbo. I need to order pipe but I need the rest of the parts installed first to plan out the route.
(Posted in: 2024 Big Turbo)

27 coated.jpg
0 hits | 67.58 KB | Posted: 10/10/24
Hot side parts back from being ceramic coated.
(Posted in: 2024 Big Turbo)

28 mount mod.jpg
0 hits | 72.29 KB | Posted: 10/25/24
Modified the drivers motor mount to have a channel to retain the clutch cable tight to the motor so it won't melt.
(Posted in: 2024 Big Turbo)

28 mount.jpg
0 hits | 56.96 KB | Posted: 10/25/24
Clutch cable sitting in the modified mount bracket. It is not going anywhere. The bend looks tight but it is less than the loop it makes at the front of the engine.
(Posted in: 2024 Big Turbo)

28 pump.jpg
0 hits | 56.12 KB | Posted: 10/25/24
Volvo power steering pump sitting on the frame rail in the bracket tacked together.
(Posted in: 2024 Big Turbo)

28 pump 2.jpg
0 hits | 61.89 KB | Posted: 10/25/24
Top view of Volvo electric power steering pump.
(Posted in: 2024 Big Turbo)

29 belt.jpg
0 hits | 76.36 KB | Posted: 11/2/24
With the pump in I could finalize the alternator mount. The final belt length was 0.5" longer than stock.
(Posted in: 2024 Big Turbo)

29 gear.jpg
0 hits | 76.96 KB | Posted: 11/2/24
New power steering lines going to the gear. Routed them along the bottom of the fan shroud with double hose cushion clamps.
(Posted in: 2024 Big Turbo)

29 pump.jpg
0 hits | 65.81 KB | Posted: 11/2/24
Lines at the new pump. Waiting on a controller to test the system.
(Posted in: 2024 Big Turbo)

30 gaskets1.jpg
0 hits | 77.96 KB | Posted: 11/6/24
One gasket shim embossed. I'll stack three shims to make one full gasket. I'll go: embossed, flat, embossed.
(Posted in: 2024 Big Turbo)

30 gaskets2.jpg
0 hits | 63.89 KB | Posted: 11/6/24
Detail of one port.
(Posted in: 2024 Big Turbo)

30 gaskets3.jpg
0 hits | 60.19 KB | Posted: 11/6/24
My little jig to emboss. I tried to use the vice to press it, but got nothing. A hammer worked fine.
(Posted in: 2024 Big Turbo)

31 engine.jpg
0 hits | 83.24 KB | Posted: 11/16/24
Replacing the valve covers.
(Posted in: 2024 Big Turbo)

31 wrapped.jpg
0 hits | 82.58 KB | Posted: 11/16/24
Hot pipes all wrapped.
(Posted in: 2024 Big Turbo)

31 engine with headers.jpg
0 hits | 90.26 KB | Posted: 11/16/24
Engine with wrapped pipes
(Posted in: 2024 Big Turbo)

31 bracket.jpg
0 hits | 84.96 KB | Posted: 11/16/24
Clutch cable bracket.
(Posted in: 2024 Big Turbo)

32 car on112524.jpg
0 hits | 87.99 KB | Posted: 11/25/24
The state of the car today. Spark plug wires installed. Oil feed to turbo installed. Oil cooler lines figured out.
(Posted in: 2024 Big Turbo)

32 oil cooler parts.jpg
0 hits | 61.69 KB | Posted: 11/25/24
The new oil cooler line routing. Not much room in there.
(Posted in: 2024 Big Turbo)

33 crimped terminals.jpg
0 hits | 42.09 KB | Posted: 11/26/24
Crimped Ford wedgelock terminals.
(Posted in: 2024 Big Turbo)

33 wire harness.jpg
0 hits | 70.74 KB | Posted: 11/26/24
Subharness laid out. Needs loom.
(Posted in: 2024 Big Turbo)

33 Oil drain.jpg
0 hits | 74.6 KB | Posted: 11/26/24
Blurry shot of the new oil drain.
(Posted in: 2024 Big Turbo)

34 oil cooler lines.jpg
0 hits | 64.28 KB | Posted: 12/5/24
Lots of plumbing stuffed around the oil filter.
(Posted in: 2024 Big Turbo)

34 oil cooler.jpg
0 hits | 65.9 KB | Posted: 12/5/24
Oil cooler
(Posted in: 2024 Big Turbo)

34 oil drain hose.jpg
0 hits | 74.92 KB | Posted: 12/5/24
Better shot of the oil return hose.
(Posted in: 2024 Big Turbo)

34 wire harness.jpg
0 hits | 85.68 KB | Posted: 12/5/24
Alternator, coolant sensor, and oil sensor wire harness.
(Posted in: 2024 Big Turbo)

34 engine.jpg
0 hits | 86.03 KB | Posted: 12/5/24
Current state of the project. Only a few things left to handle.
(Posted in: 2024 Big Turbo)

35 shield.jpg
0 hits | 58.78 KB | Posted: 1/1/25
Front fender splash shield mostly done. I need to redo the tire clearance.
(Posted in: 2024 Big Turbo)

35 shield 2.jpg
0 hits | 43.06 KB | Posted: 1/1/25
Protection from tire splash and a little bit of a cold air scoop.
(Posted in: 2024 Big Turbo)

36 inside.jpg
0 hits | 49.53 KB | Posted: 1/5/25
Version 2 inside view.
(Posted in: 2024 Big Turbo)

36 under.jpg
0 hits | 52.31 KB | Posted: 1/5/25
Version 2 view from under in front.
(Posted in: 2024 Big Turbo)

36 version 2.jpg
0 hits | 60.37 KB | Posted: 1/5/25
Version 2
(Posted in: 2024 Big Turbo)