I have the passenger side header just about done. It is tacked welded together, I just need to add a wastegate bleed off. The drivers side is also almost complete I just need to get some more elbows and integrate a wastegate bleed off on it too. I figured I would show some progress pics.

 

Ok all in all I like it but a few questions.

Is that a hose clamp on the driver side header?
For the log headers are they steped?
What is the power strip on the driver side firewall?

 

Yes that is a hose clamp. It is just there to hold the piece in place for mock up.

Yes the headers do step up. I used 304 SS sch. 10 weld els. Each tube is out of 1-1/4" and the meet up into a 2" main pipe. Keep in mind this is pipe nomenclature not actual tube size.

The power strip is for all the many accessories I have. It is a junction for a key on power source and a couple others. The car never sees bad weather so I wasn't really concerned with shielding it from the elements.

 

Ok I didn't think you where that dum but I have seen a guy try to use flex exhaust and hose clamps on a turbo with a coat hanger bent around the CHRA to hold it to the battery tray.

Look realy clean just what I like to see!

 

It looks great so far. Going with that style header should give good airflow and tight packaging much like a stock manifold. Between the better airflow and 304 SS material they should work great. The 1-1/4" elbows are right in the middle of a typical 1-1/2" to 1-5/8" header with 16 gauge wall. The 1-1/4" (1.44" ID) elbows are popular because the OD is about the same as a 1-3/4" pipe OD and makes them a perfect fit to pre-cut header flanges.

What are you tack welding the 304 stainless together with?
What are you going to finish weld them with(TIG, ARC, MIG)?
Back purging with Argon? Using Solar Flux Type B, or no back shielding?
That looks like a T3 flange, is it?

 

Thanks!
I will post some pics of the headers when they are complete.
I am having the headers TIG welded with 309L rod. THe guy that is welding these is an excellent welder, the best I have ever seen. I am not sure how he is going to final weld them, but I am fully confident in his welds.

 

A little bit closer...

 

sexy

 

where does the flange on the header come height wise to the top edge of the valve cover...inch wide...flush...little bellow...im gonna do mine soon and i was wondering how to have hood clearance but have them as close uptop as possible for heat reasons....thanx man...

 

The flange is about even with the valve cover rail. I have about 1.5" of hood clearence.

 

valve cover rail, so where it bolts to the head you mean...not the top of the valve cover and i have a ram air two hood so that should help a little any pics of this close up you have or no...thanx man

 

Check out the second pic in the first post...this is the best pic I have right now.

 

Here is the cold side. No it's not intercooled. I am going to plumb up a water injection kit for now. I am only going to be running 7psi and I am sure I will be ok. The piping is out of stainless because it was readilly available to me.

 

Nice clean set-up

 

No intercooler?

 

Nope, go up a couple posts.
I am also going to try to run E85.

 

First love the setup very very clean. Makes me want to turbo my car. I know E85 has a 105 octane rating, so i'm guessing your banking on that to offset detonation caused by higher intake temps. I also know that their have been some drivability issues because of the lower BTU output of the E85. Any thoughts on what affect that will have on the combined output of the motor, tunability...... Also those are good sized turbos are you planning on going intercooled and looking for more power later on?

 

The setup runs very well and I am very pleased with it. I am actually in the process of modifying the fuel system now to run E85. Basically just increasing the size of everything. I have been running 91 octane all summer without any detonation problems, keep in mind I am only running 7lbs of boost. I have a meth kit installed which I am sure helps out with the intake temps. I am hoping that with the E85 I can run a little more timing and maybe a little more boost. I am not too concerned with any drivability issues while running E85. I am sure I can tune for it. I am also hoping that I can put out more power while running it. I was thinking about adding an intercooler later on down the road, but I am not positive I will need to. I am sure that there is more power to be had by adding one but for right now I am happy without one.

 

Sorry I was a little ambiguous what i meant to say is that I've seen drivability issues in later model factory vehicles caused by an increased ethanol content which yields a low BTU when burned. So I guess in your case it wouldn't be much of an issue cause your running aftermarket EFI and can turn up the boost and little and play with the spark curve too. So in theory E85 on your vehicle should work very well, since you can increase your fuel to match with more boost. Very cool project, now I'm wishing I went with a dart block and low compression pistons on my current build and could play around with a boosted third gen too. Looking forward to see how this turns out for you.