Zetec Turbo

[c0alition]

Finally actually have enough parts to start work on my turbo setup. I figured I'd start a thread, and update it with pics and details as I go along.

I bought a wastegate adapter and got an adapter plate made to mount it to my stock exhaust manifold. I'll be doing all the piping to the driver side of the car; that should help me avoid all the mess on the passenger side. I took out my AC dryer to make room for the turbo to feed the bottom pipe of the intercooler.. I'll be mounting up the intercooler and piping out intake side this weekend.

[FastCougar]

One piece of advice ... create some brackets to help support all that weight. The stock header studs where sized to support the weight of the stock header/catalytic converter only.

[iceberg65]

looks like a promising build. I would defiantly be talking to turbozetectour, I'm sure his knowledge will be a valuable asset in your build.

[fordrule]

looks like a promising build. I would defiantly be talking to turbozetectour, i'm sure his knowledge will be a valuable asset in your build.

+1

[c0alition]

ooh, didn't even think about the weight part! I'll definately look into brackets.

BTW, welded intercooler brackets and mounted it up... might have to lift it up a little bit. I tested a few different ways of piping.. and I'll have to do a little bit more modding to make everything fit right. I cut out an area to fit a pipe through the stock air hole into the fender.. but the piping just seems to be too stressed and confined in the area.. and i don't want it rubbing or even breaking/cracking if I hit a bump wrong.

[99cougarOZ]

how much was it for everything in the 1st picture on the start of the thread?

[c0alition]

I'm not sure.. about $1200. The turbo is just a cheap dummy turbo to get setup.

[Turbo Zetec Tour]

I dont know if the Cougars have it or not but i know the pre98 Zetecs and all Foci have a bracket that comes off the axle bearing bracket to help support the exhaust which is why i didnt have problems with the weight. if your car doesnt have the bracket, then just fab up a bracket that goes from one of the turbo housing bolts to one of the old CAT support strap bolts.

if you have the AC removed completely, i suggest removing the condensor and mounting the intercooler behind the bumper support, the farther back you can get it the better as it will mean more clearance with the bumper.

[c0alition]

yea, took out the condenser today. Depending on how this piping works out, I may try that route. I guess it didn't really look at it much.. but is there really enough room to mount a 3" deep intercooler?

[c0alition]

yea looked at it today.. intercooler won't fit in place of the condenser. but I finally found a piping that I like and the bumper fit back on. I had to cut out the "fog light cover bracket"?? I don't know what to call it.. but after that the bumper fit fine.