03lancOZ

iTrader: (3)

HMMM... So there really isnt that much difference in the flanges.. hmmm...

Wallesasuaz

iTrader: (23)

^ wells it's not an exact match but it'll take alot of machining to make them line up properly. But besides, that, do you they even have to align perfectly? or as long as there is exhaust moving through, you'll be good to go?

senate6268

iTrader: (20)

Even after the bracket was ground off, it still hit the housing. It was after then that I had to lengthen the runners. And after lengthening the runners, the wastegate was moved closer and closer to the radiator. I've read a few stories about EVOs puncturing radiators after hard braking with their wastegates. I told my friend to keep an eye on it. Also, after about a month and a half his manifold cracked like crazy. He bought one of those SS Autochrome ones off eBay. They are so poorly made. He took it to a shop after that and had them replicate the manifold with good pipe and proper welds. Much better now.

Wallesasuaz

iTrader: (23)

Maybe you can do something similar to this and run a SMALLEr Radiator!

01G_WRX_02

iTrader: (1)

The out side ports are off, but im going to do some welding and porting to get it to flow alittle better.



After cutting the bracket off I might take a hammer and dent the pipe a little. It wont hurt the flow and cooling enfough to do anything. What kind of manifold were you using?? Mine could be different than yours. As for the SSAC header cracking Im going to make a support bracket like the Evo uses to support it better. and If it does crack I can always reweld it.

senate6268

iTrader: (20)

The manifold was an EVO VIII manifold from SS Autochrome on eBay. The actual seem welds that joined the pieces of pipe together began to crack from heat expansion. It was just a cheap manifold for a cheap price. Many a horror story can be found in regards to the "high quality" of parts available from SS Autochrome here on the boards. My friend didn't want me to dent the water pipe (I suggested it to him). So I just lengthened the runners accordingly. Pretty good looking manifold, while it lasted, though.

01G_WRX_02

iTrader: (1)

heres some pics of the flange on the SSAC header. It lines up sp much better than the stcok manifold. Also when I orded my Header off ebay it was for just the header no gaskets, no o2 housing,or hardware. But i opened the boxes and I ended up getting the gaskets, o2 housing,and hardware. so that was cool.

GSknight

iTrader: (11)

Good Stuff! I love custom turbo projects; I'm in the midst of one myself.

How much PSI is that Volvo wastegate set at?

Good luck, I cant wait to see the finished product!

01G_WRX_02

iTrader: (1)

heres the WG setting on most volvos. I got this off TurboBrick.com. Mine is
from a B23FT 6.8-7.7 psi

B21ET 5.8 psi
B21FT 5.8psi
1981-1985 240 GT Turbo 130 cu in. B21FT-I intercooler model introduced mid 1984.


B23ET 7.1 psi
B23FT 6.8-7.7 psi
1983-1989 760 Turbo
1985-1989 740 Turbo



B200ET 7.5 psi 2.0L inline-4, turbocharged, Bosch Motronic engine management (introduced for the '85 model year)
1985-1989 740 Turbo



B230ET 7.5 psi 2.3L inline-4, turbocharged, Bosch Motronic (introduced in the '85 model year)
1985-1989 760 Turbo
1985-1989 740 Turbo



B230FT 7.5 psi @ 3000 rpm
1988-90 740 HP Turbo
1989-1992 740 Turbo
1985-1989 740 Turbo
1990-92 760 Turbo
1989-91 780 Turbo
1990-1994 940SE Turbo
1991-92 960 Turbo

__________________________________________________ ___________________

****ty phone pics.


Stock Vs evo DP






just seening what it looked like with the bumper on.



This where I had to cut pipes to get it to fit . It came out good.

Wallesasuaz

iTrader: (23)

so the bumper sits flush on top of an EVO intercooler? Did you have to cut anything else besides the pipes?

GSknight

iTrader: (11)

How did you get the front of the intercooler so shiney?

I have polished mine several times, and it still doesnt look that good.

01G_WRX_02

iTrader: (1)

yes kinda does, I had to cut it very little. most of the cutting is behind the bummper.. PS to you poeple who might do this to a non OZ lancer the IC will hang below the bummper about 1inch but the OZ lip covers it on the OZ.



I just gave it a quick wet sand and them used a drill and buffing wheel.

Z_Lancer_Man

iTrader: (115)

Thats looking great so far! Nice job on doing the custom kit.

01G_WRX_02

iTrader: (1)

Heres some more pics. The stock EVO DP fits great all I had to do was lengthen it about 12 inches. I Also took the stock EVO support bracket and welded it to the DP so that when its all bolted on it with help support the turbo and header. Im just waiting for my FMU,oil return line, and gauges to come in the mail. other than that I
have to hook up the coolant lines, tap the pan, guages and the FMU and Im done.

MalibuJack

iTrader: (5)

I love seeing how much interchanges between these cars.. It makes for amazing swaps..

BTW, If you want to make your life a little easier, check out one of the mini-battery kits, you should be able to fit the battery over the motor mount next to the fuse box, give yourself alot of room for your intake in what would be the stock location for the Evo..

I'm even more impressed with how little had to be modified to the flange to get it to fit (just a few new holes drilled correct?)

I'd like to see someone do this with a stock cast manifold and make it look like it was OE on the car..