Exhaust welding complete and mounting.

Finished the last of the welding to the exhaust and downpipe, welded the hanger to the frame and installed everything. I think it came out great and there is some descent clearance to all the engine components.

Still working on the intake manifold, somehow I think its going to take longer than I originally thought, hoping to start on the intercooler mounting next week though.

The welding continues

Still welding the intake manifold, finally got all the runners attached to the intermediary plate for the plenum, need to grind the welds clean and smooth out the transition from the plenum to the runner. Also doing the final welding on the downpipe/mufflers, installed the hanger bracket, once the welding is complete on the exhaust downpipe and manifold then I will be welding the frame hanger bracket to the center of the X brace on the frame.

Intake manifold fabrication

Yesterday I started intake manifold welding, please keep in mind this is about the second time I have tried to TIG weld aluminum and its my first time trying to weld a thick material (3/8") to thinner material (1/8"), I had many problems, nothing that won't be cleaned up. Also I found out from my boss a way to get a better weld when welding materials with substantial thickness difference (preheat the thicker material with a propane torch), which I will be trying out tomorrow, so I hope it helps with welding quality and speed, so onto the pictures. What you are seeing is the 3/8" plate that will get welded to the intake plenum, with the trumpet style intake runners that should speed up air velocity, the curved entry to the intake runners should also the airflow into the ports and keep runner turbulence to a minimum. After this I will be welding the runners to the intake manifold flange (which is 1/2" aluminum) and after that I will be welding on the intake plenum.

Progress is coming

Sorry everybody about the lack of posts, there is progress, started welding the intake manifold last night but forgot my camera, also was going to finish the exhaust welding this weekend but had the exhaust hanger bracket lasered out of mild steel, not stainless like the rest of the exhaust is made of. I will have pics to post tonight.

Also on another note the next 2 or 3 weeks might be slow with this build, my daily driver (86 Fiero GT) needs a new engine/tranny combo, so I am swapping in a 3800SC 4spd muncie transmission (from the original 2.8L auto), right now I am waiting on the flywheel, motor mounts and wiring harness, hoping to make the swap in one weekend.......

New brake parts

With great thanks to John Powell from Powell Motorsports he has hooked me up with some front brake calipers, I will let the pics do the talking.

Exhaust mockup complete

Fabrication of the exhaust is nearing completion, all the cutting and tack welding is complete, just need to do the final welding and mount the exhaust hanger. I did in the end cut off the mufflers and install a S-bend in the pipes to offset the 1" needed to have the mufflers exit center on the car

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Downpipe and exhaust mock up

 Its been a couple days, but I have completed the mock up of the downpipe and exhaust systems, I still need to make the exhaust hangers and there is a slight issue/problem that most people might just let go, but its really bugging me.........the dual mufflers are 1" off center (with a slight twist but thats a really easy fix), in reality I might be able to hide the error with creative bumper design/exhaust tip design, but I am going to look into shifting it tomorrow before I do the final welding to the unit.