Originally posted by 99cougar:
if you were to use a crossover pipe instead of making all new headers, and making the piping of some slightly cheaper material would prolly reduce cost by what? $1000 or so?

it would still be intercooled, and make just slightly less power...sounds good when does production start? lol



Why do you think I did my last adaptation on my turbo kit back in early 2003? Why would I get rid of perfectly good heads, turbo headers, etc. and completely start over?
I had to make some changes to the engine and I decided I could do it cheaper and easier the second time.....So I did. It was purely an experiment with oval port heads and escape cams and stock manifolds....about as cheap as it can get. The old header pipes would have easily supported 400+ wHP since they were so big.

This current system is probably good for around 350-370 wHP at around 12-14 pounds of boost. I converted over stock manifolds to work even though the rear was completely stock the front had to be cut to fit. Those same manifolds on my 3L made the 326 wHP dynos you see on my website.
You know, I discussed the topic on my website and the potential benefits and cost reduction. Of course the manifolds I used were already gutted so I wasn't worried about keeping them the exact same, but it will work the same if you were to keep the precats were you concerned about trying to obtain compliance with cold start emissions.

I could have stuck with the original header pipes I had but I was trying to explore ways for people to turbo their cars without the high dollars. I'm sure there are a few people that have been inspired by this.
If I hadn't deployed to Iraq for a year you would already see a part 3 comparison that changes out the stock manifolds with a set of headers, MSDS/WeaponR.
Since I have been delayed a year, that is currently what I am working on now.
I have already converted the WeaponR stainless headers and made a crossover pipe for it. The only delay is that I am using Stainless for all the piping at the same time and of course my work schedule.
If I ever get the time, I can have it back together in just a few days. Then it will be tuning and off to the dyno again.
As soon as I am sure that my new pipe system will fit and does work, I am going to sell the complete pipe system that I used to make that 326 wHP, manifolds, crossover and up pipe, and down pipe along with the diablosport chip I have already tuned for 36# injectors and a lightning MAF to go along with the pipes. This will allow the buyer to bolt on piping, and all he has to do is acquire the MAF, intake filter and pipes (and intercooler), turbo.
Back in 2003 I was trying to find a way to construct a crossover pipe kit with some company using my design but it is just too much work for me. So that is the whole story.

Former owner of '99 CSVT - Silver #222/2760 356/334 wHP/TQ at 10psi on pump gas! See My Mods '05 Volvo S40 Turbo 5 AWD with 6spd, Passion Red '06 Mazda5 Touring, 5spd,MTX, Black