[bradsm87]

So I've ran the numbers on upgraded twins and inlets and it's certainly pretty up there these days with the AUD.

I'm thinking of fabbing up a twin scroll steampipe ceramic coated manifold and making jigs and documenting everything possible to duplicate it with my brother who is a very competent welder/fabricator. We usually always prefer low mount but on this platform, high mount is the way to go due to the steering column and allows for shorter runners due to the direction of rotation of the turbo with the exhaust side of the engine being on the right side. Fitting the turbine housing between the engine and the strut tower with the compressor housing being in front of the strut tower will be the plan (This will mean that this kit is not for HUGE turbos and may not fit any different turbos at all).

The advantages of the exhaust manifold over anything I've personally seen on the internet would be:

- Shorter runners AND equal length.

The kit would be offered with options to suit the BorgWarner EFR 7670 and the 8374 in either T4 twin scroll .92 or 1.05. Other turbos may work with but once the initial kit is produced, there will be no test car so modification to suit other turbos would be the buyer's responsibility (but really, why would you?). This would be a no-compromise tight-fitting setup with limited turbo compatibility rather than a one-size-fits-all product.

As this would be a project 'on the side' of a full time job, we would want to minimise financial risk and would therefore only supply manifold, any custom brackets, oil/water lines, downpipes, intake, cold side charge pipe, air filter, modded coolant pipe to block and any other minor bits needed to physically install the turbo. Everthing supplied would obviously have a full warranty. The customer would need to supply:

- The turbo
- Relocate their coolant reservoir, vacuum tanks etc.

It would be offered with either a downpipe that splits into two factory-location outlets or a 3.5" single V-banded outlet.

Please let me know your thoughts.

Cheers,

Brad

[naynay]

sign me up with factory dps

[JB4-335]

This is definitely the way to go and and as you said by the time you get a decent set of hybrids landed and installed you'd be better off with a locally fabbed single. Makes more sense to me.

[bmwheath]

Interested

[bmwheath]

External wastegate with stealth screamer pipe FTW!!!!! ; )

[timot]

I am interested

[bmwheath]

Nice power to be had with these turbos! Would also give people the chance to go a single downpipe and exhaust, would sound heaps better and a more simplified setup

[JB4-335]

Originally Posted by bmwheath

External wastegate with stealth screamer pipe FTW!!!!! ; )

Now your talkin!

[iliketurtl3s]

In

[bradsm87]

Originally Posted by bmwheath

External wastegate with stealth screamer pipe FTW!!!!! ; )

Absolutely. Another great thing about external gate with screamer is that around 30% of the exhaust flow goes through the screamer pipe so if you want super stealth, you can keep stock exhaust and it won't be a restriction.

[DR-JEKL]

Would be great to see how your kit transpires!

Have you seen the 135i 'kit' from a QLD member?

[bradsm87]

I have seen it. Good effort for the time taken and it turned out to work well. I'm a little bit more OCD myself (which is a bad thing because everything takes 10x longer). I hope to fit equal length runners, nice 3>1 merge collectors and 100% bank separation (either by going twin wastegate or positioning a single wastegate where it's possible to put a divider all the way to the wastegate valve). If space does not allow for either of those options, I'm not too keen to compromise so fitting a Tial wastegate to the turbine housing would be the next option. I did this with great success with my last car. I'll post a couple of pics shortly.

[bradsm87]

Pics from my last project. The runners are very short and within 5mm of each other in length. It would have been impossible to fit wastegates onto this one so went with adapting the turbine housing for a single gate with a divider all the way to the valve. I wanted an external gate as I wanted a very, very quiet exhaust when off boost so went with small main exhaust + screamer pipe to get the best of both worlds. The BorgWarner wastegate would have otherwise been fine.

[bmwheath]

Spewin i just sold my Turbosmart 50mm Raceport that was kicking around in the garage

[DR-JEKL]

Looks great mate!!

I know it's hard to put a number down just yet, but pricewise what would you be hoping to offer them for?

I reckon $6-8K for the manifold turbo oil/water lines DP inlet etc would be nice

Where in Oz are you located?

[bradsm87]

Originally Posted by DR-JEKL

Looks great mate!!

I know it's hard to put a number down just yet, but pricewise what would you be hoping to offer them for?

I reckon $6-8K for the manifold turbo oil/water lines DP inlet etc would be nice

Where in Oz are you located?

At a rough guess, around 8k for the lot. Keep in mind, the turbo itself costs more (and is better) than other options so if another option for 8k was for a Garrett or Precision, you'd know which option represents better value.

Location is the next challenge. I'm in Hobart and my brother who does the welding is now in Sunshine Coast I'm still considering all the options of best way to get it done.

I'm currently researching boost solenoids etc and best options for flash-only single turbo boost control. I'm thinking about adapting a stock wastegate actuator to mount to the EFR and operate the Borgwarner internal wastegate so we can get factory boost control from zero, rather from a normal wastegate spring's minimum boost. Another option would be to use a passive device that converts the DME's 1000hz PWM to 30hz.

[tawfeeqh]

http://www.e90post.com/forums/showthread.php?t=1115269

May still be expensive landed in Aus, however thread says well made kit and low price!

But most people are commenting that its not very well done...

[bradsm87]

Originally Posted by tawfeeqh

http://www.e90post.com/forums/showthread.php?t=1115269

May still be expensive landed in Aus, however thread says well made kit and low price!

But most people are commenting that its not very well done...

Looks OK to me other than not being twin scroll which is a big deal breaker for me. I just don't see the point in spending 40K on a very nice car then stooging out on not getting the best possible performance out of a turbo setup. After owning a BorgWarner EFR myself, I would never, EVER go back to anything else. Ours will have a very similar layout to that one but with shorter runners and bank separation all the way to a T4 divided flange.

My brother is keen to move forward with this so I'll get pricing for the hardware so that I can get a solid price then we'll be looking for somebody that can offer their car for up to three weeks at the Sunshine Coast for him to build the kit and in return, that customer's kit will be heavily discounted.

I'm thinking the simpler the setup, the more reliable and easier to install so what would peoples' thoughts be on only offering the .92 internal gate turbine housing option? I think $7500 should be achievable for the lot including adapting one factory wastegate actuator to the BorgWarner internal gate so that factory flash-only (or JB4 or whatever works with stock turbos) boost control can be used all the way down to 0 boost. A screamer pipe would be nice but for the extra work and cost of getting an external gate in there, I'm not so sure now.

[DR-JEKL]

Originally Posted by tawfeeqh

http://www.e90post.com/forums/showthread.php?t=1115269

May still be expensive landed in Aus, however thread says well made kit and low price!

But most people are commenting that its not very well done...

Unfortunately it's a LHD kit though, so practically as of no relevance?

[tawfeeqh]

Originally Posted by DR-JEKL

Unfortunately it's a LHD kit though, so practically as of no relevance?

Yes - as I read on further I kind of realised the kit was only for the LHD market, so yes of no relevance to us Aus. I was just interested in seeing thier fabrication work, but it didnt give too much information and the photos also didn't privide much detail.

So probably a bad thread to bring up, sorry

[DR-JEKL]

Originally Posted by bradsm87

Looks OK to me other than not being twin scroll which is a big deal breaker for me. I just don't see the point in spending 40K on a very nice car then stooging out on not getting the best possible performance out of a turbo setup. After owning a BorgWarner EFR myself, I would never, EVER go back to anything else. Ours will have a very similar layout to that one but with shorter runners and bank separation all the way to a T4 divided flange.

My brother is keen to move forward with this so I'll get pricing for the hardware so that I can get a solid price then we'll be looking for somebody that can offer their car for up to three weeks at the Sunshine Coast for him to build the kit and in return, that customer's kit will be heavily discounted.

I'm thinking the simpler the setup, the more reliable and easier to install so what would peoples' thoughts be on only offering the .92 internal gate turbine housing option? I think $7500 should be achievable for the lot including adapting one factory wastegate actuator to the BorgWarner internal gate so that factory flash-only (or JB4 or whatever works with stock turbos) boost control can be used all the way down to 0 boost. A screamer pipe would be nice but for the extra work and cost of getting an external gate in there, I'm not so sure now.

Hmm must say I would love a BW ST and at that price its great BFYB if you can offer a kit for $7.5k definitely love your approach with providing high quality turbo (great spool and reliability) yet also aiming for a achievable purchase price. I love the idea of the screamer pipe, but it wouldn't be a deal breaker for me personally...

The 0.92 housing in my amateur turbo experience would be the most popular choice. Would you be gaining these through a local supplier and what about a warranty on the fittings manifold and turbo?

[DR-JEKL]

Originally Posted by tawfeeqh

Yes - as I read on further I kind of realised the kit was only for the LHD market, so yes of no relevance to us Aus. I was just interested in seeing thier fabrication work, but it didnt give too much information and the photos also didn't privide much detail.

So probably a bad thread to bring up, sorry

That's cool, I wasn't sure if I was missing something hence why I asked in case I had missed that they had relevant info