SN95 Twin Turbo (Re)Build

Ive been hard at work lately.

My Car just recently blew its 3rd headgasket. While its apart i have decided to rebuild my turbo system. Many people said that a rear mounted system wouldent work, but it worked Great. I Only had a few issues, and they are why im changing to a front mount.
First of all, with my air filters in the side scoops, my car would suck in ungodly amounts of water....i mean it would almost stall the engine in the rain and i feared hydrolock...This could have been easily fixed by mounting the filters in the truck, etc but would have required a complete re-working of the intake system.
Next, Loudness, with the turbos mounted there...it was LOUD, i mean like a jet taking off....At first its quite fun and impresses people, but it gets annoying fast when your cruising down the highway....plus i had no mufflers, so it was also quite loud.
Last, Ground Clearance....this was the ultimate reason i decided to switch it, i mean i could fix every other problem but this...it was QUITE low, i mean i would bottom out my skidplate everywhere....it was causing damage.
The only good way to do it would be to mount the turbos higher by cutting the complete rear seat pan.

All in all though, the Turbo system worked damn good...probably full boost by 3,500.or so...so it did have a bit of lag but it wasent too bad, and the oiling system worked great with the sump pump..i was quite happy it worked so good.


This Brings me to my Next project....it seems the car is in the garage more than its driving....probably because it IS.
Anyhow, i Replaced the headgaskets and am installing a stock cam with my 1.7 rr's. The crane 2031 NA cam was causing extra lag and loosing power due to overlap. I plan on front mounting the turbos, moving my battery to the trunk, and the fusebox to the fender. I also painted my engine bay and Am hiding the wires, I also bondo'd some holes in the front Radiator support. Anyhow, enough talk- Here are some pics of my progress.

Today i Installed the heads with the new 9333-pt1 gaskets(coated with copper spray and torqued to 95 lbs with arp studs). I also finished the header flip with piping to the exhaust housing,...It will be wraped completely.

The Twins-Im contemplating fully polishing the housings

Header Build in progress(using old piping)


Header with turbo mounted


I'll Keep Updating as i Build

Thanks guys....It will be tuned at DEZ racing...he did the initial tune....before i changed the MAF causing my HG issues.

And no, it isnt painted yet, i just painted the engine bay, the car is still primer red, but it will be DSG...i allready have the paint just my money is funneling twords the engine now

Ok guys, i finally finished my headers!...and what a abortion it is.....these headers have some CRAZY bends.....but to get it to work, it had to be done.

Ok, whell first of all dont make fun of my welds because i just got gas for my mig today, and im getting used to the settings.

Also, i know the bend into the turbo on the driver's side header is a bit extreme, but i needed every bit of that bend...it will still flow ok IMO, because the exhaust housing inside dia is actually quite small on these turbos, say 2-2_1/4"....and i ran 2-1/2 tubing.

This setup Does clear the smog pump, which i NEED, because i will be able to bolt up my stock 4 cat h-pipe when i need to run emmissions....otherwise it will have an X-pipe.

what do you think? Whats nice about this setup is that the turbos will both be pointed in teh correct direction(front) and the hot side out will be quite straight and easy. I will be mounting the turbos up and ill take pics.

Also, it will be 100% heat wrapped when im done

Thanks guys! I will post some pics up soon of the progress.

Ive got the headers mounted, Turbos mounted, and down pipes done,that connect to a stock h-pipe, but will be ran with an o/r X-pipe, then to some flowmaster knockoffs through the stock tailpipes.

I also punched and tapped the oil pan with a 1/2" hose on each side for a drain.

Basically now all that is left is to complete the cold side and get the intake manifold on!

Here are the pics......Im still waiting for the heat wrap but here it is mocked up.

I was able to mount the fusebox above the driver's side turbo, which is nice because its accessible not being in the fender.

I know the welds are mean, but there getting wrapped anyway, and i think i got it down now for the cold side so it should look good.

Mufflers:

X-pipe:


Engine pics











As a side note, I installed a stock cam and pushrods, is anyone interested in a Crane 2031 cam and some Trick flow pushrods for the cam? there only about a year old. I also have a Tilton diff pump that has VERY low hours that i have as leftovers now

View attachment 474239

no, he actually cheaped out on me, he is gonna sell his mountineer, got a free bronco...sorry man it just happined. The intercooler is actually quite a small one that i had for my last kit, knowing that my piping would do alot of cooling. It should work fine for now tho....as a plus, i just mounted it directly to the bottom of the bumper and it was easy easy. Also its a 2.5" and rated to like 500hp or so.

Today i Got my lower intake on and torqued down, and my heat wrap arrived so i wrapped all my headers and downpipes. I got the sparkplugs in (autolight 104's gapped at .030) and now im going to tighten everything up good on the hot side and start on the cold side, which should go quite fast, as im only using 1-3/4 pipe for the crossover from the pass. turbo to the driver's side of the intercooler. Then through a y-pipe to 2-1/2 through the intercooler. easy easy. This is nice to build opposed to crawling under the car back and forth when i made the remote mount. Its going much faster and looks much better!

Oh, and the mufflers were from summit....i think they are very similar to flowmasters....but they look to have better built internals.

My car should be REALLY quiet now. Before with JUST the turbos only rear mounted it was about just as loud as when i had the offroad h and flows. Now with the turbos mounted front and mufflers rear its gonna quiet down alot....which actually will be nice because it got quite loud on the highway...plus where i mounted the turbos before....they were LOUD in the car, when they spooled, damn you couldent think straight.