I'm finally adding a turbo to my car. I bought a supercharger when I used to autocross. I then started to race on a track. Everything was great until I blew up the blower. I removed it then continued to race naturally aspirated. I eventually became a better driver without the boost, so now its time to add boost again.

So far I have added:

-Enhanced DIYPNP MegaSquirt
-Precision 600 intercooler
-ACT clutch and street disc
-TEIN Flex coilovers
-PWR radiator
-SS clutch, brake lines
-Carbotech XP10 and XP8 brakes
-Boss frog rollbar
-Custom CAI airbox
-DIY coolant reroute upper and lower
-PS delete with welded input shaft
-Ultrashield Rally Sport seats
-Simpson camlock harnesses
-Squaretop manifold
-COPS
-Walbro 255HP
-Other smaller details that I forgot

I contacted ARTech for SS coolant and oil lines, a top mount ramhorn manifold, 3" SS DP and exhaust with Magnaflow resonator and muffler. I purchased a BorgWarner EFR 6258 and sent it off to him.

Here are the pics of his progress...

 

I ordered a CXRacing intercooler kit. The plan is to have the pipes welded locally.

 

Here is my DIY coolant reroute to make space for the turbo and improve cooling on the track. I made the parts from a broken aluminum racing jack. The upper reroute improved cooing across the engine and the lower reroute makes more space for the turbo manifold.

 

More fab pics of the stainless 3" exhaust. It has a Magnaflow resonator and muffler.

 

Stainless braided teflon oil and coolant lines were made. I eventually ended up routing them differently due to space constraints.

 

I was getting close to receiving this kit from Abe. I know that there will be lot of small parts that I'll need to install it.

I have the following:
-wideband (I forgot to put it in the first post)
-intercooler piping with clamps and couplers/elbows
-GM temp sensor
-intercooler
-oil and coolant lines and hose

I'll need:
-mount intercooler
-temp sensor bung
-duct airflow
-make oil/coolant line bulkhead bracket
-heat shields for brake booster/manifold
-tubing for the blowoff valve
-wastegate actuator tubing
-larger fuel injectors
-drill oil pan (need drill bit and tap)
-oil catch can ?
-intake hose routing
-boost control ?
-??

I also decided to get fire sleeves for all the lines going to and from the turbo for extra protection.

I found them here: http://208.109.215.220/files/newprod.pdf

 

The turbo lines arrived after most of the turbo parts, due to being outsourced.
Here they are when I received them. Somebody got in the way as I was taking a pics.

All of the parts are steel. I used a steel BSP to NPT fitting for the block and a steel tee and a steel NPT to -4AN fitting for the line. The VDO oil pressure sender connects to the tee.

 

Here is a pic of the Precision 600 intercooler.

 

I painted the manifold with VHT ceramic paint and baked it to cure it.

 

The scariest part of the build was to drill the oil pan. I put a ring of tape on the bit to act as a stop so that I would not hit the oil pickup tube. I also greased the bit so that it would catch the metal shavings.

In order to keep the tap straight to cut the threads, I put it in a socket with a long extension. It worked perfectly. After I cut the threads, I used JB Weld to seal it to the oil pan.