DBSharp's Turbo Fabrication thread.

[dbsharp]

This is a pretty low budget build I put together. I have spent right under $800 to convert my car from NA to boosted.

Parts I got for free from Errol (yardiexd40): This stuff was part of his old setup. His new setup is going to be bad ass.
Holset HY35W type-D turbo
JDM FMIC
Tail Knock off wastegate
Waste gate dump tube parts
Front torque mount for a suburu.

Parts that I am designing/fabricating for this build:
Ram horn turbo manifold
Downpipe
BOV mount tube
Front motormount brackets
Turbo braces
Wastegate dump tube

Parts I bought, not including all the minor BS:
Turbosmart BOV. Got this for $40!
2.5" intercooler Charge pipes and couplers
Down pipe parts
Weirtech flanges for the manifold
K&N filter




















I expect this to make 250 to 300 WHP once it is done. I have dsm 450cc injectors and a somewhat small intercooler. If I want to get more power out of this setup later, I could upgrade these parts and crank up the boost! Of course I wont do this unless I get the $$ to build a motor too.

[twokexlv6coupe]

niioooceeeee


what's the red machine in the first pic? can't be a mandrel bender, since your doing pie cuts


and did you already make that ram horn mani? i might be interested in one of them suckas, if u decide to sell some

[c mak]

Nice work Dan!!!

I wish i could do some of that work you do!! The mani looks awesome. Can't wait to see the final project pics! Makes me want to go turbo again, damn it!!!! LOL

[dbsharp]

thanks for the compliments.

The manifold will turn out nice once its done, right now it still has a couple pin hole leaks in it. I am going to give it to a buddy of mine who is going to go back over the manifold with a tig welder. I have A LOT of hours into the manifold so far, I'm not sure It would be worth my time to make them to sell them.

[drummersteve7]

dude. your car pulled on the h22 and boosted ford.
now your gunna boost!

I fuckin love you man!
great work. nice to see your doin it yourself.

ETA?

[weirtech]

i'd try to eliminate most of those couplers on the charge pipe.

[dbsharp]

i'd try to eliminate most of those couplers on the charge pipe.

I don't own a tig welder. If i did I would only have a couple of them and would have welded up the rest. All of the pipe is flared at the end, so I don't foresee any issues with the couplings.

Oh. By the way, do you recognize the flanges on the manifold? they are all weirtech flanges. I was going to call in a favor and get some cnc lazer cut by a friend. I even had the flanges drawn up and dimensioned in autocad. One reason I didn't was because of all of the dimensions that are necessary for the head flange. I would rather just pay you for them than to use up the favor. Who knows what part I may need cut out in the future.

ETA? I have to find a circlip and seal for the compressor housing on my hy-35 before it will be together. I am waiting on a reply from gpopshop. Maybe I can get them there.

[Sobeman81]

what's the red machine in the first pic? can't be a mandrel bender, since your doing pie cuts

It's a horizontal band saw. Perfect for cutting long lengths of pipe.

[h22sparkle]

did you make good clearance with the crossmember with that manifold?

[dbsharp]

I designed the manifold to fit the turbo I have into the space I have available. It clears the crossmember. I did design it to be used with the traction bar I plan on making. There isn't as much room for the downpipe as I would like, but with a traction bar there will be more room.

I am using the stock radiator and one of the fans. The other fan is going to be a pusher that sits between the intercooler and radiator.

I only have two pieces left to make. The turbo brace and the waste gate dump tube.

I get my last part early next week, so this should be together sometime next week! I want to get the wideband working good before I go beating on it much.

[gdout90accord]

manifold looks sick bro, i wish i got a welder.

[dbsharp]

I don't own one. I borrowed a friends. Now I just need to make some friends with tig welders.

[dbsharp]

Every part is fabbed up. I am just waiting on my last part to come in so I can bolt it all together!

[chessboxer]

Great work!

[dbsharp]

I updated the first post with new pics.