Lots of progress finally.
Fabbed up the collector and welded the runners in place, turns out Tig welding the inside of a collector on the third pipe is a genuine pita. One full side of the headers done after a full day of welding. Decided to weld the inner side of the flange/pipe joints in order to get a good solid weld all the way around and not fight impossible weld spots. One thing is for sure, definitely never doing headers again, severely underestimated the amount of work it would be. Build would probably be done by now if I already had some.
Dropped the engine to check fit, just barely touching the aluminum mount and ecu, so probably going to eliminate or relocate. Only going to have about half inch to an inch clearance in back so may need to make some more room. Need to replace the heat shielding with something actually decent (anyone have any good heat shield material suggestions?)
Modeled up the remaining header. MUCH more working room, only took half a day this time and managed to get a good fit with the same length and bends.
Finally the fun part. Got the turbo out to check fitment. I picked up a 3" cast stainless 2 runner intake manifold … but Im not sure if Im a fan of it…. I may end up making one, but I won't be able to get as tight of angle runner bends… the cast one puts the turbo pretty far back too…. hmmmm
My original plan was to have it upright with the exhaust runners below the snail shell, but I think sitting flat will be better for keeping a lower CG and also give a bit more top clearance and keep it away from the head and throttle body.
Still deciding whether to use the 3" flex joints on the headers. I think I can get them to fit, and I know it is probably a good idea to reduce pipe stress due to thermal expansion differences… guess we'll see how much room I have to work with after the other header's done.
Last edited by wek120; 03-13-2016 at 06:26 PM.