Got the down pipe routed and welded together today..... Just need to add the v-band flange, O2 bungs and hanger to finish it but I ran out of welding gas..... Here are some progress pic's, the O2 bung are just sitting on the pipe in the approximate position they will be installed.....
Today I got a hanger bracket for the down pipe made and welded in..... I welded the v-band flange and the O2 bungs on the down pipe..... Then I put the turbo back together and mocked it up so I could figure out the position for the oil return line trough in the top of the frame..... The first attempt was a little shallow, guess I'll have to make it a little deeper tomorrow.....
Made a new piece to go through the frame deeper and got it to fit(what a pain in the a$$)..... Then put the turbo back in place with a hose attached, now there is enough clearance so I welded in in..... There will need to be some bumper bracket notching to clear the oil drain fitting(BIG SUPRISE )..... Next I reattached the down pipe and checked the clearance for the inner fender apron..... I ended up notching the factory part of the apron, pulled it together and tacked the seam in place..... Now I can get the clearance I need on the down pipe to finish the apron..... I welded that seam up and ground it down..... The only pic that came out good is after grinding it, so here it is.....
First thing was to mock up the bumper pass side bumper bracket mark it up for necessary modifications...... Then I made the forward panel first, tacked it in and mocked up the turbo to check clearance..... I welded and ground the first panel, after that I made a second panel for the other half of the apron and got it tacked in..... Here are some progress pic's.....
Welded up and ground the piece I put in yesterday and cut the clearance for the oil return line..... Then I made the piece for the core support to cap the front of the right apron, welded it in and ground the welds down on it..... Last thing today was to get the lower radiator mount started.....
Today I finished the lower radiator mount..... Then welded in filler panels on each side of the radiator to close the opening down to the core size and ground the welds down..... After that I mocked the radiator back up and measured for the to mounting bracket, then went over to work and made a top bracket to install tomorrow..... Here is the progress from the panels tacked in, welded/ground and with the rad mocked up for top bracket measurements.....
I woke up sick Sunday morning, but I did go to the shop for a while..... I just started feeling better today and figured I better get Sundays update on here..... I got the upper radiator mount made and installed..... Then I mocked up the water pump and notched the driver side front frame for clearance, and welded in some filler pieces..... Last thing I got done was to cut a hole put in the core support for the turbo inlet, and tack a ring in the back side in line with it..... Progress pictures.....
Today I finished welding and clean up on the turbo inlet opening..... I also made an adjustment to the to the core support where the top radiator mount attaches on the right side, had to split it/lower it and weld it back together..... I notch the top of the core support for more radiator cap clearance..... Then made and welded in the trans cooler mounts..... Last thing I got done was to move the car outside and clean up the mess that was under it, and I got the front sheet metal down so I can test fit it and figure out what to do with the turbo inlet area..... Here's a few pic's of the car when it was sitting outside.....
Sunday I got all the front sheet metal and grill mocked up..... Then I modified the main right front bumper bracket so it would clear all the sheet metal modifications(still need to do a mod on the outside bracket)..... There is not a lot of room in front of the turbo opening, still debating what to do for a filter..... Here's some pic's of the car, bumper bracket mods and the opening area.....