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Making my own twin turbo 350Z

Old 12-03-2018, 03:57 PM
  #21  
ChrisDe
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Oh and I also started making the structure that is going to support the radiator and intercooler. Still loads more to do on it but here's what I've got so far






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Old 12-10-2018, 04:27 AM
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Finished making the mounts for the radiator as well as new oil and power steering coolers







Hopefully get the intercooler mounted and end tanks made in the next week
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Old 12-12-2018, 04:55 AM
  #23  
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Got the upper radiator support and front bumper mounting points made over the last couple of days, as well as getting the intercooler core mounted. Although think we need to add some more strength to the front bumper support as the weight of the bumper makes it flex a bit.







EDIT:
Made some new mounting tabs for the rad/bumper frame to try and help stop it flexing (didn't help that much, but at least they look a bit nicer now lol)

Old:



New version:



Last edited by ChrisDe; 12-19-2018 at 02:54 PM.
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Old 12-12-2018, 03:24 PM
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Gorgeous!
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Old 12-13-2018, 09:26 AM
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some very nice work, can't wait to see more pics
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Old 12-13-2018, 01:37 PM
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Video of making the new front bumper support and cooler support if anyone's interested:

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Old 12-19-2018, 03:00 PM
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Started making up the intercooler end tanks this week. At first the aluminium welding went REALLY badly, and I thought maybe I was just out of practice as I'd been doing steel so much recently. But it turned out the welding torch had a leak, and once I got a new torch it was a million times easier. Unfortunately by that point I'd already tried to do a lot of the welding on the top end tank with the broken torch and made quite a mess, so I ended up going over it again with the new torch and trying to tidy it up (which is why you see the really big and slightly messy welding beads on one edge in the pictures).








Yes the intercooler is huge... I kind of regret getting the core made in that size as its proving very difficult to make the ends of the tanks actually fit, but what's done is done and that's what I've got to work with.

One other thing I got done a couple of days ago was making up the new oil cooler lines:





Last edited by ChrisDe; 12-19-2018 at 03:05 PM.
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Old 12-19-2018, 03:21 PM
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My God man, those welds are hideous! They'll haunt my dreams for days. Burned my retinas!
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Old 12-19-2018, 03:57 PM
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Originally Posted by onevq35de View Post
My God man, those welds are hideous! They'll haunt my dreams for days. Burned my retinas!
I've no idea if you're joking, cos some of them really were horrendous when I was using the broken torch and even though I tried to cover them up they still don't look great. But I tried to keep them out of the photos as much as I could haha Here's what some of it looked like with the broken torch:


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Old 12-19-2018, 04:58 PM
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Oh, I'm serious. Those welds make me want to hang myself. They make me angry. After I saw the pics, I ran outside and kicked my neighbors dog straight in the junk. Now my neighbors dog is angry.
I'm kidding.
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Old 12-22-2018, 04:28 PM
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Got the top end tank pretty much finished today... I know the outlet is pretty weird but it was the only way I could think of to make the outlet actually end up in the right place whilst avoiding hitting the headlights or radiator. Original plan was to just have a 90 degree bend come off the end tank but due to the intercooler being so large, there was no way that would fit when you consider the piping coming out of the intercooler needs to be about 3 inch diameter.



The headlights are the main reason for the weird shape. Even after all this, there's still only about 2mm gap between end tank and headlight at one point.





We also got all the intake piping in place but not fully welded up yet. This includes the very awkward pipe that needed to go from the turbo to the air filter at the front of the car (which means avoiding the steering column and trying to keep it from getting too close to the exhaust manifold).
















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Old 12-22-2018, 04:59 PM
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Looks great and probably just as good or better than many shops might do for big $.
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Old 12-22-2018, 07:56 PM
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Chris - where did you source your header flanges? What's your header runners thickness?

(I appologize if you already answered this)
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Old 01-06-2019, 03:02 PM
  #34  
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Originally Posted by bealljk View Post
Chris - where did you source your header flanges? What's your header runners thickness?

(I appologize if you already answered this)
I got the flanges from Mazworx, here: https://www.mazworx.com/store/p/31-V...st-Flange.aspx

The runners are all 1.25 inch schedule 10, which in reality is more like 1.5 inch diameter and is 2.7mm wall thickness. I was originally going to go for 1.5 inch schedule 10 but a motorsports fab shop near me said that's overkill for the power I'm aiming for and mentioned they'd had cars running up to 700 bhp on 1.25 inch schedule 10 runners.
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Old 01-06-2019, 03:09 PM
  #35  
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Nearly finished the lower end tanks on the intercooler now










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Old 01-09-2019, 04:11 PM
  #36  
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Finished off the intake piping and BOV today







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