I finally got the intercooler core test fit, and for the most part it fits perfectly behind the upper grille, but I will have to notch the front bumper support to give me some extra working room.

I also need to look into mounting my setrab cooler for the powersteering, since the loop just wasnt very adequate for what i'll be doing. I was aiming to get it behind the upper grille as well, but I dont think it will work with the way i'll have to mount it.

The endtanks will be mocked up this weekend, which means breaking out the poster board and scotch tape... yay
I do have to work around some things, but overall it should be easy, then I can take the shapes, cut them out of sheet aluminum and have turbo dave weld them up for me.

Once I get this preliminary stuff done, I will move on to mounting the e320 exhaust manifolds (reversed so the outlets are up and towards the front of the motor) Then see what it will take to route everything to my gt37, which will be mounted in between the radiator and motor on the pass. side, using the upper airduct for the intercooler piping. Im replacing the large oem with 2 small pusher fans to give me the room I need. Overall the intercooler piping will be very short, about 4ft so thats always a plus.

The passenger side exhaust routing to the turbo isnt an issue because theres nothing in the way, however the drivers side will probably require me to relocate the p.s. resi with braided lines and such, I'll draw up the mounting fitting in solidworks, have one machined and weld an an fitting on the end so that shouldnt be an issue. Im also going to look into replacing the large surge tank with somethign smaller, so I have room to run a filter off the turbo.

I'll update this over the weekend once I start on endtank mockup.. Slow progress but its progress.

IMAGE_116.jpg

 

Sounds cool my friend!!! Will keep an eye on this thread! Good luck this weekend.

 

You are certainly on the right track. I am glad to see you have not lost interest

 

Very Awesome!!

 

Sounds like a plan!

 

Wishing you success.
Keep us updated.

 

now this is a turbo thread...comes out swingin' with a plan.....good luck with your project...should be a fun read....

 

This is on a N/A correct???

 

So I did a little more work tonight, given my random bouts of insomnia.

I think I've pretty much got the turbo placement nailed down. I will have to re-route the lower radiator hose, as well as the hoses for the "rest" function water pump, but it shouldnt pose a major issue.

The one thing im wondering is downpipe routing. My original plan was to run it over one valve cover, similar to a CAI and have it come down in the normal stock position. But due to my change from twin to single turbo (more efficient, simple, etc) It looks like it might have to go under the engine. It looks like theres room enough on the drivers side the snake it through the engine mount/engine itself. Theres a gap and its sizeable, but what I also might look at is having a set of engine mounts made out of aluminum, with one side having a recess for an exhaust provision. It shouldnt be a big issue as the engine mounts on our cars seem to be overly large for no reason.

I'll work on it a bit tomorrow

 

Slow weekend due to parties and such (hey, been stuck at home a while)

Ive determined the best way to route the exhaust piping for the turbo. The passengers side will use the e320 manifold with the outlet forward, and i'll use the drivers side e320 manifold mounted the standard way and run a crossover pipe behind the motor to meet up with the passenger side, that way I can save some space and simplify things.

Wastegate is more than likely going to be a Tial 46mm, due to large displacement, low boost.

I'm still working on the intercooler piping routing as well as the downpipe, hope to have a grasp on those tomorrow.

 

yes, 10:1 is a perfectly boostable compression ratio. The weak links on this motor are going to be head bolts and the head gaskets.

If I can buy a spare set from mercedes, I'll send the head bolts to ARP to see about having studs made, as well as a spare set of gaskets to send to cometic.
Im still trying to source a stock clutch/flywheel combo to have suitable replacements made.

 

Alright, I promise to have pics soon, just wanna set things permanently before I post pics.

Figured the downpipe routing for the most part. It will run on the pass. side of the car, in between the motor mount and motor. Theres enough room to run a 3" downpipe, I have some spare 3.5" I might see if I can fit.

Definitely going with the crossover pipe for the drivers side exhaust bank

If anyone has a spare drivers side exhaust manifold I'd really appreciate it, as the e-series manifold wont fit with what I need to do.

Hopefully picking up the fic-8 at the end of week assuming rudy still has it, as well as the wastegate. I also need to source piping materials and figure out the best design for the 2-1 collector that runs from both exhaust banks to the turbo.

Im going to so sometime this week to the machine shop and have the donut hump for the gasket machined down so i can use a standard flange and gasket.

 

Extremely excited to see how this one works out!

 

I'm keeping an eye on this project too. It's going to be difficult for you but fun for us.

LEs

 

Not as hard as you would think
ive done this a time or two.

I've got every thing layed out in my mind, Im probably gonna go to home depot and grab some materials to do pre-lim mock up before i actually order the piping and such, so i have a rough idea of how much i need.

pvc piping is a good mock up for intercooler piping, I'll see what i can find in pvc to do the exhaust.
Sounds cheap, but its save me and my friends a lot of money and guess work

measure 1000 times, cut once

but this is just the mechanical side.
I still need to figure out the fueling and engine management.
hp tuners (we use it on our z06) has come out with a beta for the hemi chryslers, which from my research use the same ecu as our cars. So im going to see if it works with our ecu's thereby negating the need for the aem fic

Im also more than likely going to go with a walbro pump and add a return line to the fuel system, by way of having billet fuel rails made so i can use braided lines, etc. but this will be down the road once i get the turbo kit functional, using bigger injectors in the mean time ( i want to see where the stock pump stops)

I also have a brilliant idea for an oil cooler setup using the oil filter cap, but i need to draw that up in solidworks and have a rapid prototype made before I actually CNC one

 

I know on the SRTs it sure seems like the fuel pumps run out of breathe before the injectors do. That may not be the case for the N/As, but I thought I'd throw that out there.

Good luck with your project, definitely keep us updated.

 

The chrysler PCM is a totally different animal and isn't even remotely close to what we have in our cars. Our cars are FIC friendly though so you can still use the stock ECU, just need to make your changes through the FIC.

 

For what it's worth; those of use with NA's are 110% behind you!
Good Luck

 

So I've been looking at this every which way but sideways, The amount of fabrication involved is just not worth it for the gains. For a standard location turbo kit its just not worth it
I tossed around the idea of a rear mount before going this way and it looks like im going back to it.
I already have every planned out from my previous planning. It will be alot quicker and more cost effective.
I already have the scavenge pump and all associated parts.

I've been looking into the issue of intercooler piping routing, and due to our already low ground clearance, plus my cars underbody is 2.5 - 3" off the ground Im going to have to run it through the transmission tunnel.

Theres room at the rear for it to fit and enough room for it to run up the tunnel, past the tranny, and into the engine bay vis the gap between transmission and firewall, theres about a 3" gap which is more than enough room to run my 2.5" piping, also I'll still be running the front mount, as the thermal conductivity of the aluminum piping just isnt enough.

So, hopefully this route will go much faster... Ive been up for about a week straight mulling over how to do the engine bay mounted turbo and its extreme, alteast for what i'd be getting out of it

 

Intercooler piping is planned out, it should work, wont know 100% until i get the piping in, everything else is cake. The one roadblock is trying to figure out where to mount the scavenge pump.