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Well, it's another month and I have made huge progress on FourBanger. I have mounted the battery in the back of the car for weight transfer, and upgraded to Zero gauge welding cable for my battery cables. I found the cable at auto zone. Don't believe the parts guy if he tells you that they don't have it. Ask specifically for welding cable also. It has more strands than regular automotive cable.
The intercooler is completed and let me tell ya, It looks (and flows) awesome! I did have to send it back to the welder to have a few leaks rewelded, but I am very happy with their help. Here are some pics of the finished product.

 

When I finally got my I/C home, I did a small test using a leaf blower to see how well it flows compared to the stock volvo one. Wow! What a difference! This thing should be enough to fuel any blown 5.0, or FourBanger. hehe
I plan to use Fuel tank Filler hose as boost pipes. That stuff is so reinforced, it can't leak. I just have to find some really good hose clamps that hold a lot of pressure.

I did however find some pinhole size leaks in two of the vanes. Don't be alarmed because these are easily fixed with a little JB Weld. (Thanks to all at http://turboford.org/ for their recommendation)

The following is my turbo! The heart of the beast. I did wrap the header but was not able to wrap the neck area (by the head) due to the header bolts. I think it should help out a lot. The outlet pipe on the turbo's discharge is a Spearco part. It is made well and will do the job. I did find an outlet pipe that would do the same function and was on a Volvo (too late though). If you have a front mount intercooler, this piece is manditory.

Take a look at the inlet. Look good? LOL  Oh, I can't wait to try this out! It is soo smooth and radiused perfectly. I wana see some HP out of this little mod! I know it isn't going to equal a larger turbo, but it should definetly help.

The following pics are of my most recent find at the junkyard. I scored BIGTIME!!! I found a BMW 745 Turbo. I grabbed the discharge pipe off of it because it had a nice funnel shape to it. The thing that is attached to it is the stock bypass valve. I didn't think much of it when I brought it to the junkyard attendant's window. She didn't know what it was so I said it was a piece off of an air cleaner. LOL  The price was $5.25. So I said cool and brought it home. When I disassembled it I realized that this bypass valve was HUGE! This thing is built exactly like a brake caliper. It has seals on the piston and on the seat of the piston. Best thing about this is IT'S REBUILDABLE!!!!!

 

Needless to say, the piston has one hell of a spring! I was really trying to hold it open here. Even though it has a tough spring, when boost comes on, the boost presses the piston down even more on the black O ring seal. What a find! I can't believe I got it. I was just about to order a new bosch bypass valve for $35 bucks! Take a look at the opening and outlet size of this thing! Man! I can't wait to hear this thing work under boost! I hope to have a few sound files to download soon.

 

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