Project: Mavro Gato - 99 Turbo'd 3L

[FastCougar]

hmmm ... that 99 Taurus might be the ticket!

[FastCougar]

Houston, we have a small problem.


Wastegate inlet tube finalized. The angle allows for the best exhaust flow based on the angle of the bend to the turbo's compressor flange. Anyone who's read Corkey Bell's "Maximum Boost" can visualize the flow diagrams when he touches on wastegate placement ... I tried my best to replicate his advice.








Wastegate down-pipe flange weld close-up. My flange welds are definitely much better than my butt welds.

[jaged]

time for a lower bumper then

[fordrule]

time to remove the 5mph bumper...unless u need it for inspection.....if u do hack it up.....its still in theory there lol

[Blackcoog]

Originally Posted by fordrule

time to remove the 5mph bumper...unless u need it for inspection.....if u do hack it up.....its still in theory there lol

I'm not sure how removing the 5mph bumper will help. It looks like he may be able to squeeze another inch if he moves it up a bit but he will have to make new brackets.

[FastCougar]

Well, I have another bumper, so I might just try playing around with some different cut outs to see what works. No matter what, the intercooler needs to be raised 1.5", which is easy enough to do. All I would have to do is cut the existing bracket flush with the front support cross-member and weld in 1.5" "risers".

[fordrule]

well get on with it....after you get ur saw fixed

[FastCougar]

I never got the saw fixed, but I did buy a lot of cut-off wheels for my right angle grinder. Not the best way to cut pipes, but it works.

So, job 1 was the raise the brakets on the intercooler.


Bracket closeup.


Next, what's the point of putting in this huge intercooler and then covering 50%+ of it ... makes no sense I tell you!


Yep, it's still covered by the bumper cover ... we will have to fix that.


Before we get back to the bumper, I had to do a lot of small things to the turbo setup to get things just right. For example, I chopped the up-pipe for the wastegate down so I could lower it a much needed 1/2 inch. Also notice the new support bracket. More on that to come.


Ahhh ... a much needed 1/2 inch lower. The thermostat tube is thankfull!


Now, about that support bracket ... much needed ... it bolts to the front roll resistor bolt that goes to the transmission housing.


Let's not forget the rear bracket.


Back to the bumper. So, what's the point of trimming the bumper support and not the bumper. Pretty dumb I know, so I had to correct that.

Fear this!


Now I just need to fabricate some flarings that I can rivit to the bumper to help channel in air and clean up the appearance some. The flarings need to allow me to place some screen mesh over the intercooler to keep out rocks and such.

Unfortunately, I had to loose the fog lights and I will be loosing the washer bottle as well, but it will all be worth it when I break 450 whp

[contrapaul]

Beware the interbumper!

[sheldon729]

You had to raise your mounting bracket and i had to lower mine to fit in the big hole in the drift front