bad headers.jpg
128 hits | 102.49 KB | Posted: 6/22/24
Custom headers from Stainless Steel Headers. Nothing about these were right.

checking.jpg
112 hits | 73.01 KB | Posted: 6/22/24
Holding up bits of cut up header to see where things should go.

current.jpg
113 hits | 75.22 KB | Posted: 6/22/24
Header tacked together and checking the rest of the exhaust routing.

cut up header.jpg
105 hits | 64.53 KB | Posted: 6/22/24
Slicing up the custom headers to maker them work.

Headers tacked.jpg
106 hits | 64.94 KB | Posted: 6/22/24
Reworked headers tacked up and ready to weld.

old left.jpg
113 hits | 80.11 KB | Posted: 6/22/24
Driver's side just prior to starting the single turbo install.

old right.jpg
120 hits | 77.66 KB | Posted: 6/22/24
Passenger side turbo just prior to starting the single turbo install.

routing.jpg
123 hits | 75.77 KB | Posted: 6/22/24
Figuring out the turbo positioning.

Headers 062524.jpg
111 hits | 53.28 KB | Posted: 6/25/24
Welded the headers bolted to a 1"x3" block of cold rolled steel to keep them from warping. It worked...

Headers 062524 2.jpg
100 hits | 63.57 KB | Posted: 6/25/24
I'm not a welder, but they won't leak and won't fall off. Works for me. Once they are ceramic coated...

Dreivers header hot side mock up.jpg
99 hits | 57.85 KB | Posted: 6/28/24
Chopped up a bunch of expensive 2.5" cast stainless bends to connect the drivers header to the turbo...

4 back view.jpg
88 hits | 77.03 KB | Posted: 6/29/24
Driver's side header fully tacked up including the stub to the crossover pipe. I'll have to cut the ...

4 front view.jpg
76 hits | 70.74 KB | Posted: 6/29/24
View from the front. Plenty of hood clearance but these will be ceramic coated and wrapped when in u...

4 top view.jpg
76 hits | 72.98 KB | Posted: 6/29/24
Top view showing the twisted turn for the pipes. I looked at other ways to route things and this was...

4 bottom view.jpg
76 hits | 60.66 KB | Posted: 6/29/24
View from the bottom. The two pipes don't touch but they are close.

5 figuring.jpg
83 hits | 66.74 KB | Posted: 7/4/24
Now that the header part is done at least over the downpipe, I can start on the downpipe. First thin...

5 on the bench.jpg
76 hits | 64.19 KB | Posted: 7/4/24
Once I had it sorted out on the car, I set it all back up on the bench. Much easier to get to all th...

5 making cuts.jpg
92 hits | 62.91 KB | Posted: 7/4/24
I made this extra clamp for the dry cut saw so I can cut angles on mandrel bends. Especially on the ...

5 laying it out.jpg
84 hits | 55.36 KB | Posted: 7/4/24
Mocking up my cuts. I got the angles from the corrugated aluminum pipe. It mostly worked but it can ...

5 tacked.jpg
95 hits | 63.11 KB | Posted: 7/4/24
All tack welded up and test fitting. I can move the header, turbo, and downpipe as a unit, but it is...

6 tacked up again.jpg
83 hits | 72.53 KB | Posted: 7/5/24
Inserted one 10-degree pie cut and tacked everything up again. This time the end of the pipe ended u...

6 downpipe welded.jpg
74 hits | 54.35 KB | Posted: 7/5/24
The final (?) first couple feet of downpipe. The hard part. After this it's just angle down to get u...

7 WG bends in progress.jpg
37 hits | 47 KB | Posted: 7/20/24
Some of the bends and cuts needed to make the wastegate pipe. A lot of trial and error here as the p...

7 WG mock up.jpg
38 hits | 53.66 KB | Posted: 7/20/24
The final mockup with the pipes just held in place and marked. None of the hole are cut out yet. Jus...

7 WG pipe.jpg
42 hits | 51.54 KB | Posted: 7/20/24
The pipes tacked in place with the minimum of light tacks. Still need to cut the holes out which wil...

8 patch.jpg
41 hits | 53.65 KB | Posted: 7/24/24
I cut out a spot where the weld blew through and put a patch on it. For whatever reason the Sch 10 w...

8 tacked.jpg
36 hits | 63.82 KB | Posted: 7/24/24
Tacked the pipe in place. Looked like I had access to all the weld joints. Turned out to be tougher ...

8 final welded.jpg
63 hits | 60.91 KB | Posted: 7/24/24
Fully welded. Getting to one section of weld inside that jumble of pipe turned out to be a challenge...

8 assembled.jpg
67 hits | 63.5 KB | Posted: 7/24/24
Put the turbo, header, and down pipe stub together to plan out the waste gate merge. I need to put i...

9 header.jpg
47 hits | 82.7 KB | Posted: 7/26/24
Installed in the car to check clearances. Looks like the wastegate merge can go under the header.

9 header2.jpg
42 hits | 78.6 KB | Posted: 7/26/24
Installed in the car front view.

10 merge fitment.jpg
42 hits | 39.55 KB | Posted: 7/26/24
The merge for the wastegate return. A lot of time fitting these parts to get a nice fit. Makes it ni...

10 merge mock up.jpg
42 hits | 60.13 KB | Posted: 7/26/24
Wastegate return mockup. These are always more complex than you think they will be, but this wasn't ...

11 wastegate merge welded.jpg
68 hits | 59.51 KB | Posted: 8/1/24
Fully welded wastegate merge.

11 grinding flat 3.jpg
74 hits | 62.6 KB | Posted: 8/1/24
Starting to tackle grinding the flanges flat. My 6x48 belt sander just barely has enough range to ge...

11 grinding flat 2.jpg
64 hits | 59.89 KB | Posted: 8/1/24
A little more sanding. Getting better but the ends still had a long way to go and stainless is a pai...

11 grinding flat.jpg
61 hits | 62.22 KB | Posted: 8/1/24
To help the ends out, I ran a bead with no filler right where it was warped to pull it back but made...

12 sanding.jpg
54 hits | 60.96 KB | Posted: 8/3/24
Nearly there with sanding these down.

12 done sanding.jpg
34 hits | 59.19 KB | Posted: 8/5/24
Done sanding these. I ended up buying zircon abrasive belts for the belt sander which worked a lot b...

13 header fix1.jpg
39 hits | 62.2 KB | Posted: 8/9/24
I put the headers on the car to check thing out and start fabricating the crossover pipe. For the fi...

14 Down pipe.jpg
62 hits | 99.54 KB | Posted: 8/9/24
Took the current 3-inch X pipe out and mocked up the new 4-inch down pipe to the X. I'll put a v ban...

15 X pipe cut for merge.jpg
17 hits | 47.85 KB | Posted: 8/14/24
Cut the X off where it would just overlap the new merge. I didn't leave enough meat in that weld to ...

15 Merge mockup.jpg
25 hits | 44.85 KB | Posted: 8/14/24
Merge sitting on the old X. I'll need to hammer both parts to get a better fit.

15 Merge inside.jpg
25 hits | 48.13 KB | Posted: 8/14/24
A few gaps. Hammer and welder will fill it in.

16 Merge fitted to pipes.jpg
43 hits | 25.5 KB | Posted: 8/19/24
Put the exhaust back in the car and braced the pipes so they don't move around. Then trimmed and ham...

17 welded merge.jpg
28 hits | 52.96 KB | Posted: 8/21/24
Merge section MIG welded to the existing X pipe, now it's a Y pipe. Hadn't used the MIG in a while s...

17 Merge inside.jpg
30 hits | 47.9 KB | Posted: 8/21/24
Inside the merge with the welds cleaned up a little. In one spot there was a lot less overlap than t...

17 Merge paint.jpg
27 hits | 53.49 KB | Posted: 8/21/24
I always paint my exhausts black with BBQ paint. It dries in minutes, protects the metal, hides any ...

17 merge paint plus.jpg
28 hits | 65.86 KB | Posted: 8/21/24
The 4-inch down pipe will go that way. This is just a mock up but shows the eventual route.

18 down pipe fab.jpg
24 hits | 70.33 KB | Posted: 8/28/24
Made a cardboard angle finder to figure out the angle of the downpipe and the length needed. Plenty ...

18 gasket embossing tool fab.jpg
28 hits | 50.17 KB | Posted: 8/28/24
Step one in making a jig to emboss a small sealing ridge on the stainless shim gaskets. Made the sta...

19 pipe fab.jpg
45 hits | 56.07 KB | Posted: 8/31/24
Downpipe fabrication in progress. The end of the pipe ended up exactly the right length on the first...

19 under car.jpg
42 hits | 57.71 KB | Posted: 8/31/24
Downpipe all tacked in place. I cheated on the tacks under the car and just used the MIG. Not like i...

19 Downpipe Tacked.jpg
43 hits | 64.74 KB | Posted: 8/31/24
Down pipe layout. I can get the front section in from above and the back section is easy to install ...

20 crossover pipe 2.jpg
19 hits | 33.79 KB | Posted: 9/14/24
Figuring out the bend angle and lengths for the last section of crossover pipe. Cut strips of carboa...

20 crossover pipe.jpg
31 hits | 76.13 KB | Posted: 9/14/24
A view of the crossover pipe in progress. The last three pieces are just tape in place so I can figu...

20 Alternator mount.jpg
22 hits | 77.02 KB | Posted: 9/14/24
The new alternator mount. It is the stock late Fox body Mustang part. Not expensive brand new from L...

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. ...

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 w...

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...

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 somethi...

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

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

24 drivers side.jpg
14 hits | 76.87 KB | Posted: 9/26/24
Final pipe driver's side

24 passenger side.jpg
13 hits | 77.11 KB | Posted: 9/26/24
Final pipe passenger side

24 crossover steering.jpg
12 hits | 51.38 KB | Posted: 9/26/24
Final crossover pipe with clearance to steering.

24 down pipe.jpg
15 hits | 58.52 KB | Posted: 9/26/24
Final downpipe

24 all pipe.jpg
15 hits | 101.11 KB | Posted: 9/26/24
Final pipe all before coating

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 ...

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 ...

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 ...

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...

27 coated.jpg
0 hits | 67.58 KB | Posted: 10/10/24
Hot side parts back from being ceramic coated.

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 ...

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 b...

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.

28 pump 2.jpg
0 hits | 61.89 KB | Posted: 10/25/24
Top view of Volvo electric power steering pump.

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 s...

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 doub...

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.

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, e...

30 gaskets2.jpg
0 hits | 63.89 KB | Posted: 11/6/24
Detail of one port.

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....

31 engine.jpg
0 hits | 83.24 KB | Posted: 11/16/24
Replacing the valve covers.

31 wrapped.jpg
0 hits | 82.58 KB | Posted: 11/16/24
Hot pipes all wrapped.

31 engine with headers.jpg
0 hits | 90.26 KB | Posted: 11/16/24
Engine with wrapped pipes

31 bracket.jpg
0 hits | 84.96 KB | Posted: 11/16/24
Clutch cable bracket.

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 line...

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.

33 crimped terminals.jpg
0 hits | 42.09 KB | Posted: 11/26/24
Crimped Ford wedgelock terminals.

33 wire harness.jpg
0 hits | 70.74 KB | Posted: 11/26/24
Subharness laid out. Needs loom.

33 Oil drain.jpg
0 hits | 74.6 KB | Posted: 11/26/24
Blurry shot of the new oil drain.

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

34 oil cooler.jpg
0 hits | 65.9 KB | Posted: 12/5/24
Oil cooler

34 oil drain hose.jpg
0 hits | 74.92 KB | Posted: 12/5/24
Better shot of the oil return hose.

34 wire harness.jpg
0 hits | 85.68 KB | Posted: 12/5/24
Alternator, coolant sensor, and oil sensor wire harness.

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

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.

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.

36 inside.jpg
0 hits | 49.53 KB | Posted: 1/5/25
Version 2 inside view.

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

36 version 2.jpg
0 hits | 60.37 KB | Posted: 1/5/25
Version 2

36 wheel side.jpg
0 hits | 35.45 KB | Posted: 1/5/25
Version 2 view from the wheel.

37 air intake pipe.jpg
0 hits | 62.3 KB | Posted: 1/12/25
Figuring out the turbo air intake pipe.

38 pipe hole.jpg
0 hits | 78.41 KB | Posted: 1/29/25
Cut the hole for the intake pipe on the passenger side.

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

38 finished pipe top.jpg
0 hits | 59.02 KB | Posted: 1/29/25
Finished pipe from above.

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

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...

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.

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

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.

39 lower pipe complete.jpg
0 hits | 58.29 KB | Posted: 2/1/25
Final lower pipe.

39 figuring out angles and length of pipe.jpg
0 hits | 78.03 KB | Posted: 2/1/25
Laying out the upper pipe.

39 figuring out angles.jpg
0 hits | 60.19 KB | Posted: 2/1/25
Figuring out the angles to cut

39 laying out pipe.jpg
0 hits | 65.46 KB | Posted: 2/1/25
Cut angles. Measuring for the straight section

39 pipe mock up.jpg
0 hits | 83.71 KB | Posted: 2/1/25
Final mock up.

39 bead rolled.jpg
0 hits | 37.5 KB | Posted: 2/1/25
Rolled bead

39 turning vane layout.jpg
0 hits | 63.61 KB | Posted: 2/1/25
Laying out turning vane.

39 turning vane weld holes.jpg
0 hits | 51.07 KB | Posted: 2/1/25
Drilled holes showing the vane installed on the centerline.

39 turning vane thottle body side.jpg
0 hits | 39.82 KB | Posted: 2/1/25
The throttle body side.

39 turning vane intake side.jpg
0 hits | 51.02 KB | Posted: 2/1/25
The intercooler side

39 final pipe in place.jpg
0 hits | 86.15 KB | Posted: 2/1/25
Final pipe fully welded with fittings.

40 coupler.jpg
0 hits | 74.17 KB | Posted: 2/6/25
45 degree coupler

40 intake.jpg
0 hits | 40.91 KB | Posted: 2/6/25
Air intake inlet.

41 intake pipe line up.jpg
0 hits | 42.58 KB | Posted: 2/12/25
The alignment on the turbo outlet.

41 intake tube.jpg
0 hits | 52.94 KB | Posted: 2/12/25
Turbo intake coupler final trim.

41 intake mock up.jpg
0 hits | 65.66 KB | Posted: 2/12/25
Turbo air intake mock up.

41 intake mock up 2.jpg
0 hits | 67.59 KB | Posted: 2/12/25
Turbo air intake mock up.

42 air intake with filter.jpg
0 hits | 47.99 KB | Posted: 2/21/25

42 air intake.jpg
0 hits | 69.27 KB | Posted: 2/21/25

42 intake weld.jpg
0 hits | 56.15 KB | Posted: 2/21/25

42 spark plug issue.jpg
0 hits | 70.59 KB | Posted: 2/21/25

42 gasket trimmed.jpg
0 hits | 59.26 KB | Posted: 2/21/25

43 area to grind.jpg
0 hits | 80.14 KB | Posted: 2/24/25

43 passenger side.jpg
0 hits | 73.96 KB | Posted: 2/24/25

43 driver side.jpg
0 hits | 49.16 KB | Posted: 2/24/25

43 engine.jpg
0 hits | 76.49 KB | Posted: 2/24/25

51 dipstick.jpg
0 hits | 72.66 KB | Posted: 5/7/25
Dipstick shield to stop oil drip - not effective

51 heat sheild3.jpg
0 hits | 45.63 KB | Posted: 5/7/25
Heat shield

51 heat sheild1.jpg
0 hits | 58.59 KB | Posted: 5/7/25
Heat shield installed

51 heats sheild2.jpg
0 hits | 68.01 KB | Posted: 5/7/25
Heat shield installed

55 new oil feed line.jpg
0 hits | 84.38 KB | Posted: 7/8/25

59 fitting.jpg
0 hits | 44.49 KB | Posted: 8/21/25

59 fitting2.jpg
0 hits | 49.02 KB | Posted: 8/21/25

60 Wires.jpg
0 hits | 60.24 KB | Posted: 9/1/25