The DIY SN95 Turbo Time Line

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Vic Kermode and Myself started the Turbo Build up on Sunday October 1st 2006. We have never done anything like this before, Vic is a B-Pressure Certified Welder and Fabricator. I was fortunate enough to talk him into giving this a try. I will be very honest with you i cant weld, Vic can! I would like to give him a bit of praise for all his hard work and attention to detail, it was very fun working with him and learning a few metal working tricks. (view the DIY Turbo Pictures)

Sunday (Start)

I had already removed the blower from the SN95 and it was in Naturally Aspirated State when it arrived at Vic's Welding Shop. We unloaded all the Mandrel Bends, turbo parts and pieces.

Step #1 remove radiator, any anything else that could be damaged or would be in the way. (Aproximatly 4 hrs to get the car prepared)
Cut away fender area for turbo,
Flip Shorty Headers around (facing front of car)
Install Ford Motorsport Oil Filter Adapter (90 degree)
Grind off Ball Flanges from Headers
We spent a pile of time trying to figure out where each part would go and how we would route our piping for the wastegate, downpipe and BOV.

With the 3.5" Inch intercooler there isnt alot of room from the radiator to the IC Vic welded up a small plate to the frame of the car and a vertical bar. Next we mounted up the intercooler and began working on the 1st sections of pipe.

12 Hrs of time was spent with 2 of us up till this point!

Monday

Pick up Flex Joint for cross over pipe from MoPac AutoSupply here in Edmonton $50.00 (CAD)
Mount flex joint into cross over pipe.
Make merge sadle from drivers side header to cross over pipe.
Continue building up pipe. We ran into a small problem in this area the offset to where the turbo was going was only 1.5" from the pipe to the center flange of the turbo. Very little room on the SN95.
This took a bit of Fancy work on Vic's part. He had to make the round up pipe flow into a square hole for the T4 Tubo Flange.
This took a bit of messing around but when it was done WOW NICE JOB VIC! Using his tin bashing skills he formed the pipe perfectly to the hole!
By the end of the Day (10 hrs) we had the headers done the cross over, the flex joint and the Turbo flange. Next we did a bit of work on the downpipe. I could only find a 3.5" exaust flange to fix the housing which ment we had to make a flared section to go from 3.5 to 3 Inches.
After slicing the 3.5 inch pipe in 12 places we took a chain vice and cramped it around and squished it until it was 3".
The downpip was easy until we got to where the k-member / tranny and unibody all come togather at the lower edge of the car.
After a pile more playing around with a few pieces on starnge angles we built up out parts. The trick was "could we remove it" :>) and yes it Just makes it.

Tuesday -

Late day start rounding up some more parts that we needed.

Wednesday -

Vic pulled the headers and cross over pipe out, finish welded and ground the joints out.

Thursday -

Friday -

Made it to Vic's at about 10:00 am and we started work around 10:30 had to have some coffee and bullshit!
Cut out old exaust back to the flowmasters
We now had the 1.5" piping to make the wastegate overflow pipe, so that was about 3 hrs of time to make it up, cut and merge it to the dp. Remeber Vic is a perfectionist, he ground the welds down to nothing so that the piece looks like a factory made single pipe. And i was thankful it sure made it look NICE!!!
All parts are built now including the connection to the 3 inch exaust under the car.

9.5 Hrs.

Saturday -