Jon - some interesting points there.

I don't see much option with regard to the "S" intake. Have seen this on quite a few cars and there hasn't been much said about the pros and cons of this setup...so far!

Yes, I think you re-inforced the point I was trying to make regarding a well thought out, designed and fabricated manifold...it isn't cheap!

Anyhow, some more info/pictures on the adaptor and flanges...

A T3 flange vs the Toyota exhaust flange


Another view...


The adaptor that sits between the turbo and the exhaust manifold


The fitment against the manifold


And the fitment against the turbo - doesn't look good, needs some work I think

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

I agree to a certain extent but the whole reason i believe kris is doing it this way is to reduce costs, also try something different.To get the manifold manufactured to your spec would be no cheaper than buying a proven one. Until you present me with a reasonably priced perfect fit for all garrett flanges i think i will stick with what i have my friend.What your saying to me is my setup is Crap(S#!T) as you put it, well we will see soon enough.
There is a huge variation of setups out there and nearly all have some advantages and down falls.Im not having a dig at you, your knowledge of the 4 is not in question here but you have to realise unless someone is willing to experiment (invest money on alternate designs)then we would never improve on what has already been tried.
I believe this manifold has been proven so far upto 700bhp in the states.






Hutch

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Please take your nails out of my dash..........501.1 Whp

Cracking pics kris.
Stick with it mate.
Hutch

_________________
Please take your nails out of my dash..........501.1 Whp

Nice equal runners, good size.

How long will the wastegate actuator last for, looks like it could get well hot..

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Black UK 96 205 shed with heater full on telemetry.

project six million dollar 185, faster, stronger, lighter than before.

Hutch, in that last pic is that XS Power on the left, your manifold on the right? What is your manifold?

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02 Mini Cooper Race Car
94 ST205 Import
92 ST185 Carlos Sainz
www.mcnab-racing.co.uk

You have to remember that Kris's car is his daily driver. I woudl be looking at sticking with cast manifolds too as any tubular manifold seems to crack at some point. Must say though that "full race" manifold or rams horns looks liek a fantastic no compromise design.

Is it tapped for individual O2 sensor ports on each runner hutch?

The only thing I have seen in all the above setups that concerns me a little is the position of teh wastegate port off the manifold. All will rely on there being enough pressure in teh manifold to change the airflows directio by 90 degrees. Not ideal if you wnat to run low boost in yor Ubber turbo setup for daily use. I woudl liek to see the wastegate port more inline with teh airflow direction say 45 degree off whack.

Kris - nice piccies (wheres teh spark plug gone?) I agree that the port matching is terrible so far and woudl require work. Dont forget that some step to a larger port from a smaller port - manifold to turbo or from head to manifold may reduce flow reversion in teh event of Ubber cams.

_________________
JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

Just to answer for Hitch, it is tapped for individual runner EGT probes


Yes I have noted what yourself and Datajon have mentioned but I am finding it a little difficult to think of an improved setup that would have the actuator more in line with the exhaust gas flow


Yep agreed, seems that a step hole to larger hole in the direction of flow will help with reversion

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Yes the manifold on the left is the XS poo,i agree totally with DJ on that manifold is very poor indeed.only lasted 6 months before the first crack apeared,when on the rollers it went almost clear and then spat flames out the cracks.Apart from the HKS manifold my guess is the fullrace manifold is the only real option ATM.I personally think the set up kris is going for will be suprisingly sucessful.
At the moment i am running 0.8 bar of boost on a gt35R and a 44mm wastegate and holding boost perfect,will soon be running 1.8 ish if all goes well and i will know more about the distance of the wastegate to the manifold.Tial have a very high temp spring and should hold boost no problem.
Hutch

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Please take your nails out of my dash..........501.1 Whp

Small update on the turbo installation...

My new downpipe is nearing completion, hurrah! Just a couple of lambda boses to fit and the tack welding to fully weld up

Apologies for the quality, taken with my phone...

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Nice looking pipework Kris I particularly like the flexi wastegate recirculation pipe. Quality of the welding looks the biz.

P.S. Have now acquired JP's H&S system as per your suggestion!

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Am pleased with the design, particular attention was paid to making it as smooth flowing as can be.

If anyone wants one of these systems please contact me asap as I'll be removing the JIG from the workshop in a week or so...

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

Presumably this downpipe would only fit a 3S-GTE Rev3 ST205 with an OEM exhaust manifold, your external wastegate and adapter and a GT3071 turbo?

Shame it wont fit my 'centred' Corolla WRC manifold. Also, I'd need a different wastegate pipe

_________________
Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

In a nutshell yes.

I think this is the only route open to "enthusiasts" since either alternatives are very rare, don't fit, waaay too expensive or of very poor quality/reliability...

Shame no-one is making a good quality replacement kit, then there would be a lot more higher powered cars about


I think you may well struggle keeping the aircon awith the centred Corrolla WRC manifold. The room around the compressor is tight with the stock manifold, and moving the manifold outlet to the centre will only exasperate that situation. Mind you, the turbo will sit higher in the car since you will not require an adaptor for the ext wastegate...

Look forward to seeing your pictures as the project develops!

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement

It's looking good there Kris

Well it will be once the flanges are welded not tacked lol

I wonder if it's worth making a heat shield up for the cooler doughnut. It's certainly going to get fried by the wastegate pipe in that location, not that there's much choice on that front

As you say it's a shame that aftermarket equipment is either ruinously expensive or ruinously rubbish.

I'd like to run the same turbo as you but the hassle puts me off at the moment. Will you be retaining the jigs for future reference?

Well, it's been shown in the past that shielding the 185 oil filter helps reduce oil temps, so I suppose the same applies here, albiet that it's the cooler, not the filter as per the 185 setup.

I have a cunningly plan to fit an engine oil cooler from this location and junk the stock water/oil sandwich plate style cooler...we'll see!


I like this turbo and should prove to be a good setup. The jig will be available fo rapprox 1 week for other setups to be manufactured, after that it'll be a bit more difficult...

Think Don also sees this particular turbo is a good 'un - albeit his is undergoing the obligatory "Don" customisation to enhance its performance that little bit more!

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
_______________________________________
Turbocharging - the replacement for displacement