Project: Mavro Gato - 99 Turbo'd 3L - Page 44

contrapaul · 08-24-2007, 11:34 AM

Quote:

Originally Posted by FastCougar

One ENTIRE day this weekend will be dedicated to working on the Cougar. Imagine that ... an entire day ... I'm soo excited

Seriously though, the work on this car has been done in 3-4 hour sprints when time allows. Considering the car is up on jack stands in the driveway, I think the wife wants it done as much as I do

Nice, entire days are really the only way to get big things done... what's going to change?

FastCougar · 08-24-2007, 11:42 AM

Well, the up-pipe has been redesigned and welded. The only thing left on the "hot" side is to finish the up-pipe (final section with flange on it), mount the turbo and then start/finish the down-pipe. Once the up-pipe is finished, I plan on running a bit of pipe extension from the turbo flange out past the hood and then starting the car. This will be done for two reasons: 1) discover any leaks in my exhaust tubing and 2) blow out any metal shavings before mounting up the turbo ... oh yeah, and 3) because it will be hella cool and loud

By the end of that day, I plan on having the turbo mounted and the exhaust fully routed to where it mounts up the stock cat-back. I also hope to be finished with wastegate install as well. I will get plenty of pictures and probably some video of the car starting with the exhaust routing out the hood

J-Man · 08-24-2007, 01:45 PM

You must get a video of the new exhaust you're putting on there.

FastCougar · 08-24-2007, 02:22 PM

Hopefully I have enough time to install my boost gauge. I just picked this up from BoostController.com ... I got my WideBand from them along with all my Silicone Tubing ... great company to deal with!!!

http://www.boostcontroller.com/index.php?item=355

FastCougar · 08-24-2007, 08:55 PM

Well, here is a preview of what I have in store for this weekend:

Up-Pipe almost done ... you can see that I had to cut and reweld how the Y section fit. A picture further down will show why I had to do this:

Before:

After:

A different angle to show the "up" bend.

View showing ground clearance ... roughly 2.5" inches less, but it's between the wheels, so I only have to watch out for things sticking up in the road ... speed bumps won't be a problem.

Under the car view (overview).

Transmission clearance.

And now the up-pipe to frame clearance. THIS is why I had to reweld the pipes. Before, this clearance was a mere 1", now it's closer to 4"-5". This is where the down-pipe will exit toward the rear of the car.

Oil drain plug can be removed without a problem, but oil will no doubt get ALL OVER the piping.

Up-pipe entrance into the engine bay ... clearance is greater than this picture illustrates. I would estimate it at around .5"-1".

Plenty of room to drain the transmission oil. Even with the way I'm routing the down-pipe, I don't see this being an issue. This is also a perfect picture to show the "tunnel" that the down-pipe will squeeze through.

Plenty of room for a turbo!

How the turbo will be oriented. Note the 45 degree slope to the mounting position ... this is critical to facilitate down-pipe routing to ensure plenty of space.

Engine/Turbo overview shot. Note that the turbo will actually be sitting roughly 2-3" lower and about 1-2" more toward the engine. Disregard the down-pipe orientation ... that will be rotated 90 degrees clockwise and will then beind inward.

sheldon729 · 08-24-2007, 10:43 PM

WOW im jealous. Thats going to be one nice set up. You should make them and sell them on request once you got the prototype done

I hope you making brackets for your y-pipe cause it looks like its pretty close to the tranny where it starts coming up and its yelling I wanna rub lol

gamiller · 08-24-2007, 11:29 PM

Very well done! Props!

FastCougar · 08-25-2007, 12:57 AM

Yes, braces are in the works to support the weight of the turbo. I just need to account for thermal expansion.

StealthyWeasel · 08-25-2007, 12:58 PM

you did an awesome job making those pipes, trevor!!

BurritaSVT · 08-25-2007, 01:21 PM

You really do have a nice setup I was wondering for a second how you were going to fit that 3 downpipe then I saw you removed the AC to fit it better. You are over half way there and I cant wait to see the dyno numbers on that beast. joey

08-24-2007, 11:42 AM	#432 (permalink)
FastCougar In search of more boost! Join Date: Nov 1999 Location: Kearneysville, WV Posts: 8,507 Images: 743	Re: Project: Mavro Gato (56K ... Get a cup of coffee) Well, the up-pipe has been redesigned and welded. The only thing left on the "hot" side is to finish the up-pipe (final section with flange on it), mount the turbo and then start/finish the down-pipe. Once the up-pipe is finished, I plan on running a bit of pipe extension from the turbo flange out past the hood and then starting the car. This will be done for two reasons: 1) discover any leaks in my exhaust tubing and 2) blow out any metal shavings before mounting up the turbo ... oh yeah, and 3) because it will be hella cool and loud By the end of that day, I plan on having the turbo mounted and the exhaust fully routed to where it mounts up the stock cat-back. I also hope to be finished with wastegate install as well. I will get plenty of pictures and probably some video of the car starting with the exhaust routing out the hood __________________ 1999 Mercury Cougar - Turbo'd 3L. Status: Parting out car: Engine for Sale \| Trans for Sale Power: 391.9 hp @ 6750 rpm \| 374.2 lbs/ft. @ 4250 rpm \| boost @ 11 psi For Sale: 19" Konig Verdicts with Toyo ProxesFZ4 225/35ZR19 Tires - $700 shipped!

08-24-2007, 01:45 PM	#433 (permalink)
J-Man Moderator Join Date: Jun 2004 Posts: 11,724 Images: 5	Re: Project: Mavro Gato (56K ... Get a cup of coffee) You must get a video of the new exhaust you're putting on there. __________________ "How a politician stands on the Second Amendment tells you how he or she views you as an individual... as a trustworthy and productive citizen, or as part of an unruly crowd that needs to be lorded over, controlled, supervised, and taken care of." -- Representative Suzanna Gratia Hupp (TX)"

08-24-2007, 02:22 PM	#434 (permalink)
FastCougar In search of more boost! Join Date: Nov 1999 Location: Kearneysville, WV Posts: 8,507 Images: 743	Re: Project: Mavro Gato (56K ... Get a cup of coffee) Hopefully I have enough time to install my boost gauge. I just picked this up from BoostController.com ... I got my WideBand from them along with all my Silicone Tubing ... great company to deal with!!! http://www.boostcontroller.com/index.php?item=355 __________________ 1999 Mercury Cougar - Turbo'd 3L. Status: Parting out car: Engine for Sale \| Trans for Sale Power: 391.9 hp @ 6750 rpm \| 374.2 lbs/ft. @ 4250 rpm \| boost @ 11 psi For Sale: 19" Konig Verdicts with Toyo ProxesFZ4 225/35ZR19 Tires - $700 shipped!

08-24-2007, 08:55 PM	#435 (permalink)
FastCougar In search of more boost! Join Date: Nov 1999 Location: Kearneysville, WV Posts: 8,507 Images: 743	Re: Project: Mavro Gato (56K ... Get a cup of coffee) Well, here is a preview of what I have in store for this weekend: Up-Pipe almost done ... you can see that I had to cut and reweld how the Y section fit. A picture further down will show why I had to do this: Before: After: A different angle to show the "up" bend. View showing ground clearance ... roughly 2.5" inches less, but it's between the wheels, so I only have to watch out for things sticking up in the road ... speed bumps won't be a problem. Under the car view (overview). Transmission clearance. And now the up-pipe to frame clearance. THIS is why I had to reweld the pipes. Before, this clearance was a mere 1", now it's closer to 4"-5". This is where the down-pipe will exit toward the rear of the car. Oil drain plug can be removed without a problem, but oil will no doubt get ALL OVER the piping. Up-pipe entrance into the engine bay ... clearance is greater than this picture illustrates. I would estimate it at around .5"-1". Plenty of room to drain the transmission oil. Even with the way I'm routing the down-pipe, I don't see this being an issue. This is also a perfect picture to show the "tunnel" that the down-pipe will squeeze through. Plenty of room for a turbo! How the turbo will be oriented. Note the 45 degree slope to the mounting position ... this is critical to facilitate down-pipe routing to ensure plenty of space. Engine/Turbo overview shot. Note that the turbo will actually be sitting roughly 2-3" lower and about 1-2" more toward the engine. Disregard the down-pipe orientation ... that will be rotated 90 degrees clockwise and will then beind inward. __________________ 1999 Mercury Cougar - Turbo'd 3L. Status: Parting out car: Engine for Sale \| Trans for Sale Power: 391.9 hp @ 6750 rpm \| 374.2 lbs/ft. @ 4250 rpm \| boost @ 11 psi For Sale: 19" Konig Verdicts with Toyo ProxesFZ4 225/35ZR19 Tires - $700 shipped! Last edited by FastCougar; 08-24-2007 at 09:34 PM.

08-24-2007, 10:43 PM	#436 (permalink)
sheldon729 NECO Member Join Date: Jun 2006 Location: Canada, Alberta Posts: 685	Re: Project: Mavro Gato (56K ... Get a cup of coffee) WOW im jealous. Thats going to be one nice set up. You should make them and sell them on request once you got the prototype done I hope you making brackets for your y-pipe cause it looks like its pretty close to the tranny where it starts coming up and its yelling I wanna rub lol Last edited by sheldon729; 08-24-2007 at 10:52 PM.

08-24-2007, 11:29 PM	#437 (permalink)
gamiller Emission Test Flunkee Join Date: Jun 2001 Location: Fairfax, VA Posts: 2,783 Images: 5 Blog Entries: 3	Re: Project: Mavro Gato (56K ... Get a cup of coffee) Very well done! Props! __________________ Roush Performance Suspension Nautilus Performance Stage 3 Turbo Kit

08-25-2007, 12:57 AM	#438 (permalink)
FastCougar In search of more boost! Join Date: Nov 1999 Location: Kearneysville, WV Posts: 8,507 Images: 743	Re: Project: Mavro Gato (56K ... Get a cup of coffee) Yes, braces are in the works to support the weight of the turbo. I just need to account for thermal expansion. __________________ 1999 Mercury Cougar - Turbo'd 3L. Status: Parting out car: Engine for Sale \| Trans for Sale Power: 391.9 hp @ 6750 rpm \| 374.2 lbs/ft. @ 4250 rpm \| boost @ 11 psi For Sale: 19" Konig Verdicts with Toyo ProxesFZ4 225/35ZR19 Tires - $700 shipped!

08-25-2007, 12:58 PM	#439 (permalink)
StealthyWeasel NECO Member Join Date: Sep 2005 Posts: 4,123 Images: 5	Re: Project: Mavro Gato (56K ... Get a cup of coffee) you did an awesome job making those pipes, trevor!! __________________ Currently: 215whp/194wtq runs 14.4@97 The new plan: 04/05 3L, Wrapped WR Headers, WR Y Pipe-->2.5"ss QTP electric dump valve in place of cat, SVT Cams, SS3/Fidanza, 24# Injectors, Dyno Tune, Quaife LSD + B1 Gearset

08-25-2007, 01:21 PM	#440 (permalink)
BurritaSVT NECO Member Join Date: Aug 2007 Posts: 166	Re: Project: Mavro Gato (56K ... Get a cup of coffee) You really do have a nice setup I was wondering for a second how you were going to fit that 3 downpipe then I saw you removed the AC to fit it better. You are over half way there and I cant wait to see the dyno numbers on that beast. joey

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