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)

36 wheel side.jpg
0 hits | 35.45 KB | Posted: 1/5/25
Version 2 view from the wheel.
(Posted in: 2024 Big Turbo)

37 air intake pipe.jpg
0 hits | 62.3 KB | Posted: 1/12/25
Figuring out the turbo air intake pipe.
(Posted in: 2024 Big Turbo)

38 pipe hole.jpg
0 hits | 78.41 KB | Posted: 1/29/25
Cut the hole for the intake pipe on the passenger side.
(Posted in: 2024 Big Turbo)

38 finished pipe all.jpg
0 hits | 65.36 KB | Posted: 1/29/25
The drivers side pipe from the turbo to the intercooler.
(Posted in: 2024 Big Turbo)

38 finished pipe top.jpg
0 hits | 59.02 KB | Posted: 1/29/25
Finished pipe from above.
(Posted in: 2024 Big Turbo)

38 pipe progress.jpg
0 hits | 71.9 KB | Posted: 1/29/25
Pipe in progress. Just finished mocking it up.
(Posted in: 2024 Big Turbo)

38 pipe tacked.jpg
0 hits | 52.38 KB | Posted: 1/29/25
Pipe tacked together and test fit. Had to retack it a couple times. Aluminum tacks are not as strong as steel and it turns out they break.
(Posted in: 2024 Big Turbo)

38 finished pipe up.jpg
0 hits | 68.81 KB | Posted: 1/29/25
The finished pipe from above at an angle you can see both sides.
(Posted in: 2024 Big Turbo)

39 lower pipe tacked.jpg
0 hits | 51.23 KB | Posted: 2/1/25
Passenger lower pipe tacked in place
(Posted in: 2024 Big Turbo)

39 lower pipe stick out and start of upper.jpg
0 hits | 84.31 KB | Posted: 2/1/25
Tacked pipe mock up showing the amount of stick up.
(Posted in: 2024 Big Turbo)

39 lower pipe complete.jpg
0 hits | 58.29 KB | Posted: 2/1/25
Final lower pipe.
(Posted in: 2024 Big Turbo)