The Quest Never Ends-LS Turbolader Installieren

[Nick_08]

"A true hotrodder wouldn't be content until he had created a car so violent, so hairy, so totally sick that the very act of dropping the hammer would result in instant death. Anything less results in the need to go faster."
-Tony DeFeo

Ladies & Gentlemen - I’m going to try documenting my build progress here. Here’s what I’m starting with: 1990 325iS with a cam/intake LS1 & T56 transmission. I did a half-assed build thread on it here somewhere. It’s mounted with Sikky parts.


My goal is to do this build right the first time, no BS (given my capability). The LS1 is only good for about 600 horsepower or so with the stock internals; so I have read. Eventually I intend to build a forged 4.8 or 5.3 to replace this power unit. I am designing this system to be a capable of sub 1,000 horsepower with minimal modifications (basically the fuel system being the limiting factor). I’ll end this intro post with a picture. Go ahead sub, ask questions, call me out, or tell me to GFYS. Or lurk. Cheers - Nick



^ Unlike OJ's glove, this S369 fits so she's gettin what she deserves.

[Nick_08]

Part I: Exhaust

I'm starting this build with the exhaust as it is the most challenging aspect of this build. I found these cast stainless steel manifolds that speedway sells which fit pretty damn good. I will be looping the exhaust around the motor mounts into a t4 twin scroll flange. I will be running twin 44mm waste gates. You will see the placement as the build progresses. Columbia river mandrel screwed up my order and forgot the 2.25-3" cones so I'm stuck waiting until those come in the mail. All the welding is done with millermatic 211 mig, I'm not the best welder but I get the job done. The whole system will get wrapped anyway because clearances are so tight. I have to contain the heat the best I can. You can see I cleaned up the inside of the welds with a carbide burr and sandpaper roll. Same with the turbine housing. You will see I added some steel inserts to serve as guide pins for the flange and turbine housing to ensure perfect alignment every time. Last I fabbed up a bracket to mount the exhaust to the cylinder head. More to follow...on to the pics.

[Nick_08]

[Nick_08]

Cones came in... Sent from my iPhone using Tapatalk

[Nick_08]

Exhaust finally completed, very tedious work. With mig you’ve got no control over the heat so you have to make many small tack welds and let the parts cool to avoid war page. Check out the wastegate prioritization. I will be wrapping this all soon. Sent from my iPhone using Tapatalk

[Nick_08]

Here is a look at the heat exchanger, will be working today getting this properly rubber mounted. Sent from my iPhone using Tapatalk

[Nick_08]

Exchanger is mounted, built a grille to keep rocks out of it. Exhaust is wrapped. Currently working on a new throttle linkage and brake system. Went with a wilwood pedal box. Sent from my iPhone using Tapatalk

[Nick_08]

Got a bunch of things going today. Deleted the c101 and ran wiring through the blower compartment (you will see why I did this later). Roughed in the starter and alternator cables with 2 AWG. Throttle cable has been installed and the throttle linkage modified. Last the down pipe has been made, 3.5” and none of it touches haha.

[Nick_08]

Sent from my iPhone using Tapatalk

[Nick_08]

Fuel pressure regulator is mounted, love the rivnut tool. Went with a Tial 50mm BOV and twin 44mm WG units from VS racing. It was worth it to me to save money here for the time being. They are nice units, pulled the diaphragms and changed the springs, no issues. Bench tested them and they are solid. I will be sure to set overrun boost cut should something catastrophic happen with them. And last an inside view of the linkage. Just wanted it out of the way to make room for the fuel system and brake reservoir on that side of The firewall.

[Nick_08]

I’ve gotta say, PTFE AN hose is so easy to work with and assemble. It almost seems too easy... BTW go to Menards I their pliers section and grab these cutters, they are badass, chomp the line no problem and they only cost $10 vs the pair summit wants is like $75. I got the brake system laid out, installed the bulkhead fittings. I had to redo the downpipe-I forgot about the coils and plug wires needing to fit. There is like no room. I managed to gain about an extra 1”. Also got the intercooler set and made a bracket. You can’t see underneath is two 1/2” rubber mounts with studs. On to the pics...wait I almost forgot. If you need brake lines Pegasus will make them custom to order, not bad on the pocketbook either...check it out.

[Nick_08]

[Nick_08]

Finished the intercooler mount and fabbed up a quick little pump mounting bracket. Here you can see how the plumbing is laying out in the car. Bottom port of the heat exchanger feeds the bottom of the pump. Top port of the pump will feed through the fender well to the intercooler. The top port of the heat exchanger will run all the way to the trunk and take water from the tank. The other port of the intercooler will return water to the tank. Clear as mud? The pump is just a simple 500gph rule unit. It should be effective. If not I can upgrade, they get very expensive. A lot of folks run rule 2000gph in-tank pump. So that’s a potential option should I need more flow in the future. Lastly, there’s limited space in the e30 for 3” intercooler pipe. Good luck finding oval aluminum. Trick is to take your 3” and make it oval with a press. It’s hard to tell in the picture but the oil pan actually sits lower than the intercooler pipe. On to the pics.

[Nick_08]

Heat shielding and powder coat...

[Nick_08]

Perhaps the moderator can move this thread to the project forum?