"Ray's AKA demonfire's XR4Ti build up"

[Ray]

Waiting on a few bits again (couple 90 degree couplers, some 1" OD aluminum tubing for the BOV flange, etc)

GN compressor housing


comparison to stock wheel - the GN wheel is not closer to the camera. used blue loctite on reassembly (right, joe?)


rounded over lower intake - this is about 1/2 way thru, it's a lot more rounded over now.



NPR intercooler mounted with a couple small aluminum brackets - simple is.


C&R radiator (not fully "raised") this is about 3/4" lower than full mount, just checking clearances


FC mazda RX7 oil cooler, it's like it's made to go here. Clearance, drivers side


pass side


modified the in / out to be 2.5" instead of 2.75 (yes, i flared the ends so there isn't an abrupt change)


hot side charge tubing done. Might put a proper 45 degree in, but i didn't have any kicking around, and the bend is fairly smooth.


Next up is finish cold side, weld bung for IAT / BOV, then wastegate actuator bracket, and that should be that.

[DSPXR4ti]

Is that the smaller NPR intercooler or I should say what NPR did it come out of?

That looks like a really nice set up. Whats the dimensions or your NPR intercooler just to see.

Ben

[Ray]

It's the larger of the setups - got it from TTruck - out of Cali.

[Ray]

Had a vision of one of the milspec nylocks coming loose, so i went thru, replaced them, and used blue loctite as well. Got some work done yesterday. Revised hot side charge tubing, got the intake manifold installed, throttle body, cold side tubing, wastegate actuator bracket fabbed up, mounted, turbo reinstalled and downpipe put back on. Almost ready for a test fire, but... in removing my konis i broke a brake line so, well, been in contact with mike

a little 234 loctite




revised tubing


Thinking of while i'm at it changing the exhaust too but i really like the current set up so i'm not sure i will.

[anglin]

Had a vision of one of the milspec nylocks coming loose, so i went thru, replaced them, and used blue loctite as well.

I think you need to also safety wire them. I'll come by and watch.

Seriously though, I can't wait to see this intake in operation.

[DPDISXR4Ti]

Coolest looking 2.3T intake I've ever seen

I haven't checked in on your work in a while Ray - now I see why you were asking about my planned intake - may need to incorporate a clear top to mine too!

Are you "trail-blazing" in using the clear polycarbonate, or has this been done before? Just wondering how it will hold up over time.

[John Brennan]

Are you "trail-blazing" in using the clear polycarbonate, or has this been done before? Just wondering how it will hold up over time.

This would be my only concern as well, and/or that over time, you would no longer be able to see through the thing-- reminds me of 60's/70's TV commercials: "that floor had yellowed..."

[Ray]

I had never seen it done, Brad. I figured what the heck, why not? If it yellows, cracks, or fails, then i'll just put an aluminum top on. I have the technology.

I got the car fired with the new setup yesterday. You really cant see anything in the intake until you do a light rev and let off the throttle. The sudden change in pressure turns the air inside the plenum into more of a condensate (ie, a cloud) for about 1/2 second. So it's clear, clear, clear, cloudy, and instantly clear again. pretty neat.

[DPDISXR4Ti]

You need one of these now....

[hEaT]

I have one of those

What you really mean is he needs this:

[Esteban]

How will the T3 behave with the GN wheel and cossie hotside? Still have quick spool but ability to build 20+ lbs of boost reliably? Or is there a trade off anywhere?

[DSPXR4ti]

How will the T3 behave with the GN wheel and cossie hotside? Still have quick spool but ability to build 20+ lbs of boost reliably? Or is there a trade off anywhere?

This is what I think is going to be the best turbo for autocross. just my .02

Ben

[Ray]

I'm not entirely sure yet, i'm thinking slightly more lag, if any with more top end flow.
I'll be sure to let you know.

[DPDISXR4Ti]

What you really mean is he needs this:

He'd need to add some food dye to see it better I think. Somewhere in the basement I have all the stuff for a water injection system. Just need to find the box with extra time.

[Ray]

Okay, got a little bit done.

Got some silvia type plastic flares - you'd be surprised how difficult a time i had on finding plastic ones - most are fiberglass. Ordered these in late november, and a long walk from poland later; they arrived mid january. (eBay) Color matched yesterday. Today is going to be spent cutting the rear quarters then welding in steel to fill the gap that is left, then put these on.

Anyway, not much for pictures - i haven't been photo documenting like i used to. Most of what i'm doing is not exciting at all, albeit time consuming.



Tape on rear is the cut line, i also need to clean up the fronts.

Here is a quick pic of final mock up of cold side, pre tig'ing on the bov flange, etc etc.


Alright, that took a lot less time than i had budgeted, but overall i'm pretty happy.

Please ignore poor image quality.

Cut.


Ready to weld.


Still smokin'.


After that, tape car some more, hit with flappy wheel abrasive grinder to smooth out, prime, then...

I'm pretty pleased with the result.