Header: inverted II
6/27/6
This is number 3 that was not completed and the 2nd one that mounts the turbine housing upsidedown. If you remember the previous one ( click here ) was unequal length and was made to use an external wastegate off one of the runners. On this one below there was an issue with the external wastegate/runner location and we had also ran out of Els so we temporarily halted it and finished the unequal length one. This newest one too will have the turbine housing inverted but will have equal length runners unlike the others we've made; the first and second ones were very close. Each runner on this one has 4-90s & 1 straight tube 1" long and a small section about 20 degrees just off the cylinder head flange to position the collector to mount the turbine housing in the best position in the space provided. The runners on this stay further from the shock tower and plug wires. External wastegate on this will come off of the turbine housing.
7/24/6
First it was made to line up with the ports evenly so each runner had a similar configuration. One bend then a direction change for the other three that slowly rotate to line up with the collector. Cylinders one and four have the short section at the collector to allow those to be higher to fit the other two under them. Cylinders two and three have the short sections on the opposite end to make all four equal length.
You can see the runners all have the same basic shape. I didn't do the math for the length of a curved section but if I used 3.75" for one then from the head to the turbine housing that would put each runner just about 20"
8/3/6
It's all welded and now has to be surfaced then coated. As mentioned the turbine housing will hold the external wastegate from the same port the internal wastegate had used except it will be ported as much as allowable and the dump from that will plumb back into the downpipe. The flapper for the internal wastegate will be removed. We will use an oil filer relocation kit that feeds the oil cooler and have a second filter off that adapter for the turbo feed. The pressure sending unit can be in the filter adapter or in the side of the block where the n/a motor has their sending unit. We could have easily tilted the turbine housing outward and been able to keep the stock oil filter but didn't want it by all the heat that will be down there and wanted to keep as much distance from the shock tower as possible. I think a stock Mitsubishi filter might even fit on there as those are a little smaller than most aftermarket filters.
You ask why have the turbo on the bottom like this? Well not just to be different there are some advantages, for one the air intake is lower thus a shorter pipe=less restriction, the compressor housing is going to point down like in the picture above and will have one bend to point forward through the radiator support and into the new intercooler and the downpipe will be shorter and not have the sharp angles as before, the water and oil feed line will use AN fittings and hoses as the previous header did ( click here for that ) and the oil return will be improved. The oil return will go out the cartridge down and into the oil pan sump like a DSM. There will be a short tube from the oil pan, actually the stock C/S tube from the cartridge but coming off the pan and pointing up and connect to the turbo with a section of hose. There is allot of oil fed to the turbo and this will put that oil back directly into the sump and not have to rain down the front of the motor and fly all over everything before it hits the baffle on the pan and then have to spill over into the sump. This also makes for shorter plumbing in the intercooler. We are designing a new oil pan baffle using a hinged door to keep the oil under the baffle and in the sump on hard acceleration. An additional oil return line from the cylinder head off the cover plate where the mechanical fuel pump would mount to dump into the sump all the extra oil that is pumped into the valve train under higher max rpms the motor will turn and from the added pressure from not having the silent shafts. That added oil being pumped up to the head must drain out the back down through that one port into the block or splash over the front so this extra return tube should aid in recovering the oil. In the end with those changes to the oil return path and the baffle in the oil pan we just may finally be able to do some donuts and not kill an engine in the process.