Project 1 from Injected65. Twin Turbo Kit

[Injected65]

I was recently tasked with converting my friends 1986 Mercury Capri from an F2 Procharger over to twin turbo's. As he is my friend I decided to build him the turbo kit versus buying one. I started off with having the flanges all laser cut at a local fab shop out of Stainless plate. The header tubing is all 16ga 304 SS, 1.75" diameter. This is really my first project using SS tubing. It will definitely be a learning curve.



I then started tacking up the headers.




I forgot to take a closeup picture of the other side but here they both are fitted on the engine.




I still need to adjust the collector length on the drivers side. Once I get my back purge setup working I will fully weld them.


Here is a picture of the turbo's mounted. I will take a closer look at the chrome moly mount when I have it back off the car for paint.

[charger891]

very nice build!! he`ll definately need a solid bottom end for those turbo`s!

[Injected65]

It's plenty solid thankfully. SVO block, Bryant crank and Manley billet steel rods. The F2 that was on it before was pushing about 35# of boost and the car made right around 1200 rwhp. The new turbo's are from Precision turbo and are the new PT6766 with CEA exhaust wheels. They rate them at around 925hp each. I doubt we will make them out right away, but at some point i'm sure we will. The goal is to get the car to run 4.99 or quicker in the 1/8th mile on 275 radials. The previous best was 5.30 on the radials and 5.15 on slicks with the blower.

Chris

[burner]

Looks like a great start! Did you buy pre bent tubing and cut it to fit? One day I want to try and tackle some headers so I'll be watching.

[Injected65]

I bought all of the mandrel bends from Columbia Mandrel Bending and then cut them up to fit. The V-Band assemblies I bought from Race Parts Solutions. The collectors I think were from Stainless Works. I ended up changing how the turbos mount due to space constraints. As soon as my replacement pedal arrives from Everlast I will be able to fully weld everything up and hopefully have it running by the end of the month.

Chris

[burner]

Couldn't buy everything in one stop huh. That's kinda a drag but at least you got everything.

I've read a few articles in CarCraft and some post online but I'm still a little lost on the logistics of it all. Like how in the world are you welding up those merge collectors when there is seemingly no space for the torch? Do you cut the tacks from the flanges after mock up and weld each primary alone then put them back in place and weld it all together?

[Injected65]

I could have bought it all from Stainless Works, but I just shopped around where I could find deals here and there to save a few bucks. What I did was tack everything together first. Then once everything is in place I will cut the tacks on the collectors and pull them off. Then cut the tacks from the tubes to the flanges and then weld each individual tube. Once those are welded I will put them back in the flange and weld the flanges. Then lastly I will weld the collector spike between all 4 tubes and then weld around the outside of the collector to finish things off. At least that is how I have it planned in my head. I would have really liked to use double slip collectors, but on this job the budget just wasn't there.

Chris

[burner]

Sounds like a plan. I'm not into turbos so I had to google what a double skip connector even was, lol.

[Injected65]

Here is a pic of the completed project. I ended up having to angle the turbos for packaging reasons. It hit the track this past weekend. Had a bunch of new combo issues, but by the end of the night it was making full passes. Next outing is on June 23rd and we can see what it will really run.

[Injected65]

Sorry about the big pic, ran out of time to edit the post. Here is a pic of some cool SS exhaust flanges that a buddy is making. These will help clean up where the downpipes stick through the fenders on the car.

[Injected65]

For those interested, we are using the new Boost Leash boost controller from Leash Electronics. It works very similar to the AMS-1000 boost controller but is a good bit cheaper.

[hokiefd]

Nice. So you are using CO2 to control the wastegates?

[ncsugrad2006]

Niiiice

How did you mock up the headers? Or did you just go to town?

I saw some videos on YouTube that use PVC pipe to mock them up and build a jig out of them, then you build the header from the jig outside of the car to make it easier to get to everything.

[Injected65]

Yes, there is a 2.5# CO2 bottle mounted inside the car with a 85# regulator attached to the boost control solenoids.

I just kind of went to town really. I had pictures of a few other header designs that I went off of for inspiration. I put the flange on the head and put the collector kind of the general area I wanted it to end up at and then built the first primary. From there I took the parts off and bench built the rest with numerous times taking the header on and off the car for clearance checks.