import_trung

1 problem with USDM parts, and getting them to fit on UKDM/JDM cars is the obvious LHD/RHD differences.
This difference was a problem with the Full-Race ram horn turbo kit for the s2000 that the customer purchased for his vehicle.
The brake booster, steering column and abs unit fouled the ram horn manifold on his JDM s2000, which meant the turbo kit took a back seat in his closet until a RHD kit was made. 1.5 years later, he couldn't wait no more, and so went in search of a custom turbo kit. most places booked him in, and kept on rebooking him, as they were swamped with work. Annoyed by that fact, he asked if we (angel-works) could turbo his car.
We agreed to take on the project, and collaborated with Solid-fabrications. And in 2 days, we have designed and mocked up a sidewinder bottom mount manifold, 3 inch downpipe and exhaust, and boost piping. There are a few things left to do, (wg, bov, weld everything together) but the major components are in place.



Apologise for the fone camera pics, will be getting better pics taken once the manifold is complete.

The original design was to go with a sidewinder top mount setup, ala inline pro/love-fab, but then that wouldnt allow a 3 inch dp, as they dont have the steering column to contend with. Being a bottom mount, angling the turbo at 45degrees, or there about wasnt gonna be easy, especially trying to turn the 3 inch downpipe around the vtec solenoid and oil filter.

heres a few pics of the kit being made.

making a temporary jig to hold the turbo where we want it.


20 hours later and the manifold, dp, exh system, boost piping is done. i did take pics of the process inbetween, but thought i'd load the best pics.



heres some pics of the turbo kit on a mock engine we had lying around.





we ran out of straight sch10, and had to make do just to get the manifold complete, but the long section on no4 will be gettin replaced.


heres pics of the turbo brace/manifold support



another triangular gusset will be added for further support.

the collector clears the bonnet/hood with about 10mm to spare. an oil filter relocator will be needed with this kit.
best of all, a 4 inch d/p will fit aswell, but the customer specified a 3 inch dp and exh.
the turbo hangs 7mm from the chassis cross beam, and theres lots of space for the wastegate.
best of all, there are only 2 boost pipes, suprisingly, you can manoeuvre the boost pipes into place, even though they are such long weird shape pieces.

material used:
sch10 3mm for the manifold
cnc milled 12mm stainless turbo and manifold flange
2.5 inch stainless hot side boost piping
2.5-3 inch stainless cone and 3inch cold side boost piping
3 inch stainless dp and exhaust.
6mm stainless turbo brace.

all TIG welded, and manifold will be back purged.

more pics will be added when the kit gets finished

AndyFloyd

looks great man! i love custom stuff :-)

GrandMasterKhan

thats a nice approach. I like it

berlinas2k2

Mora pictars!

kutsujula

I like!

hondabim

wow, sweet
i had the same problem/ i have a RHD and all the good kits" full race,ur. lovefab, ect can not fit because the steering column!!!

i had to go with the mini me mani from lovefab. i had to take out my abs and run stright to my master cyclinder...

your work looks A class, well done, cant wait to see the finish product!

import_trung

UPDATE!!!!

Solid-Fab got the materials in to make the jig, so mass production can start if there is a demand.
heres a few pics



with the jig made, the manifold can be taken apart to be welded up properly.





the turbo flange and the dp flange were bolted to a solid ally plate to prevent warping whilst welding.




waiting on more sch10 piping to finish the rest of the manifold off.
stay tuned for more updates

import_trung

more welding progress today

backpurging the collector




welding inside the turbo flange


welding on the runners






close up of the welds

TRBOKEV

Very nice work.

bjjs2k

excellent idea on the brace, keep us posted.