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Jake.Lowther

Rear Mount Turbo (DIY)

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Hi All,

 

Let this be the official start of my DIY rear mount turbo thread. Firstly I would like to thank @andybp (who previously has made a DIY rear mount) for helping me out with parts and knowledge. This is not going to be a quick project I'll try to keep this updated but we'll see B)

 

This project has been set back by a month or so after I injured my hand cutting exhaust pipe for a friend. I ended up severing the main radial artery, 10% of the muscle round my thumb and a couple of nerves. Had plastic surgery on it for an hour. Moral of the story wear protective gloves when working around metal.

 

(Slightly gruesome pics of stitches no blood)



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So to get the ball rolling I've installed a piggy back UTEC ECU.

 

Along with that I had to do a tad of welding to get an AFR sensor in the decat pipes

 

(Images below)

 

 


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Following on I got my hands on some C section mild steel and some mild plate so I've welded those up to make a resorvoir which can hold roughly 1.8L of oil. I also bought a cheap sight glass and threaded bung as a filler cap.

 

 


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I'm not the best at welding I've only recently got into it with no experience I just bought a Hawk 160 TIG and haven't even gone through my first bottle of gas yet :lol:

Edited by Jake.Lowther
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Following this be interested in another rear mount build :thumbs: 

 

Welding is practice, practice, practice - I spent a couple of weeks teaching myself aluminium Tig welding this year and got to a passable level :thumbs: 

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Got my new intercooler all mounted up had to make soms simple brackets and drilled and tapped holes into the crash bar. I've ordered some An6 lines and a load of fittings along with oil pressure regulators and guages. I'm running a standalone oil system with turbowerx oil pump.

 

20181202_165012.jpg.e5f418b1925ba405ddc26053ade1e416.jpg20181202_165001.jpg.0a18765ba1cd428afadf044b6529242b.jpg

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Nice to see it moving along, Can I just say, and I'm not trying to put down your hard work, are you sure that those 4 bolts are enough to hold the weight of the intercooler?

The problem more being that when you start going over bumps it will put a strain greater than just the intercooler weight on them, my concern is that the bumper ally is quite thin, there wont be many threads in it. I did a similar thing with my oil cooler and decided to drill all the way through and use threaded bar to hold the brackets.

Just a thought I'd hate to see you get it all together and then have the intercooler drop,

 

Keep up the good work :thumbs: 

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50 minutes ago, Keyser said:

Nice to see it moving along, Can I just say, and I'm not trying to put down your hard work, are you sure that those 4 bolts are enough to hold the weight of the intercooler?

The problem more being that when you start going over bumps it will put a strain greater than just the intercooler weight on them, my concern is that the bumper ally is quite thin, there wont be many threads in it. I did a similar thing with my oil cooler and decided to drill all the way through and use threaded bar to hold the brackets.

Just a thought I'd hate to see you get it all together and then have the intercooler drop,

 

Keep up the good work :thumbs: 

I thought that at first but for now its strong there's also a third bracket you cant see on the back of the strut bar wuth another 2 in.i guess only time will tell it won't go anywhere since it has about 50mm clearance from my under tray.

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18 minutes ago, Jake.Lowther said:

I thought that at first but for now its strong there's also a third bracket you cant see on the back of the strut bar wuth another 2 in.i guess only time will tell it won't go anywhere since it has about 50mm clearance from my under tray.

See that's cheating - you didn't tell us there was a third mount :lol:

 

Its probably covered then :thumbs:

Like I say wasn't putting the work down just trying to help :) Keep the updates coming :) 

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1 minute ago, Keyser said:

See that's cheating - you didn't tell us there was a third mount :lol:

 

Its probably covered then :thumbs:

Like I say wasn't putting the work down just trying to help :) Keep the updates coming :) 

Haha I think its overkill for what it is.

 

Cheers and its a totally valid point my bench testing could be completely wrong and I might eat my own words :lol:

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Made a start on welding up the pipe from the exhaust to the exhaust side of the turbo. Still on my first bottle of Argon with no previous experience I think it's confident to say I'm a natural when it comes to Tig welding :lol:

 

20181208_141410.jpg.5ea7b511f0dda483519847fd239973bb.jpg20181208_142954.jpg.0e9b10a6d59f559641e7aa18e2b6eefc.jpg

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11 hours ago, Jake.Lowther said:

Made a start on welding up the pipe from the exhaust to the exhaust side of the turbo. Still on my first bottle of Argon with no previous experience I think it's confident to say I'm a natural when it comes to Tig welding :lol:

 

20181208_141410.jpg.5ea7b511f0dda483519847fd239973bb.jpg20181208_142954.jpg.0e9b10a6d59f559641e7aa18e2b6eefc.jpg

And for my next trick, make my arm go invisible!

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20 hours ago, Jake.Lowther said:

Made a start on welding up the pipe from the exhaust to the exhaust side of the turbo. Still on my first bottle of Argon with no previous experience I think it's confident to say I'm a natural when it comes to Tig welding :lol:

 

20181208_141410.jpg.5ea7b511f0dda483519847fd239973bb.jpg20181208_142954.jpg.0e9b10a6d59f559641e7aa18e2b6eefc.jpg

I'm glad you're so good, I know who to come to now ;) now get back to work

:)

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While I've had a load of time off I've been cracking away and have turned a junk piece of 1.5mm mild steel sheet scrap into this art piece

 

For those who don't know its a custom MAF adapter plate, there are threaded stainless nuts wealded to the rear of those holes.

 

This will then be welded to the intake pipe which I'll make another post about over christmas since its almost complete.

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On 19/12/2018 at 23:29, Jake.Lowther said:

Made a start on welding up the pipe from the exhaust to the exhaust side of the turbo. Still on my first bottle of Argon with no previous experience I think it's confident to say I'm a natural when it comes to Tig welding :lol:

 

20181208_141410.jpg.5ea7b511f0dda483519847fd239973bb.jpg20181208_142954.jpg.0e9b10a6d59f559641e7aa18e2b6eefc.jpg

Like the work.

But, are you welding studs into that or do the bolts sit flush? Just as it looks too close to lay a nut/washer flat.

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17 minutes ago, Daisyduke said:

Like the work.

But, are you welding studs into that or do the bolts sit flush? Just as it looks too close to lay a nut/washer flat.

It's tight but my nuts and bolts fit :lol:

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More welding and cutting today got the majority of the intercooler to throttle body pipe work done, tad more todo then I'll post a pic of it on the car. Been just cutting bits of pipe and taping it together to see if it fits and clears everything in the bay. Just finished welding the last bits for today.

 

Feat Megan the dogo.

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Edited by Jake.Lowther
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I ran mine like that for a while, just put a cone filter on the end of the intercooler, meant I didn't have to keep putting the car back together to use it 

:)

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3 hours ago, andybp said:

I ran mine like that for a while, just put a cone filter on the end of the intercooler, meant I didn't have to keep putting the car back together to use it 

:)

I have hose clamped a microfibre clothe over the opening since i don't have any 2.25" filters but I'm not driving it just start it up to move it about my garage.

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