pete25r's bugeye progress by pete25r

4 minute(s) of a 83 minute read

COBB intake? well the part that has the MAF in it was on the car when I bought it, it's called an SF intake or somecrap. It's like $130-something on COBB's site I think? The MAF to inlet tube was like $75. Stock one had some cracks.

Some details on the airbox I made.

I picked up a sheet of aluminium from an ACE hardware, it was something like 28x28. I fabbed up an airbox out of cardboard (pizza boxes work well). Made adjustments to the cardboard until I was reasonably happy with it. Measured cardboard and the cut and bent alum. sheet to fit. For bending it I made a metal brake out of 2 large C clamps and 2 pieces of 1x3 wood, using a rubber mallet to get some decent 90* bends. I cut out another piece of alum to double up on the side that was next to the engine, doubled up for better heat deflection. I took the smaller piece of alum and C clamped it to the main peice and drilled some holes in both pieces. I put some washers inbetween the two pieces as I was pop-riveting them together. A good side effect is that it made it a good bit sturdier. I also cut some pieces to attach to the bottom so I could bolt it down to the frame.

Anyone attempting this will probably want to have these tools on hand...

2 largish C clamps - for brake

2 1x3 boards - for brake

rubber mallet - for using brake

sharp box cutting knife - to cut large/long portions of aluminium

metal snips

drill with metal bits

pop rivet tool with rivets

washers that will fit over rivets

sheet aluminium - steel could be used but would be heavier and harder to work with

dremel with some grinding bits

cardboard and tape for pre-fab

*SAFETY EQUIPMENT* eye protection and gloves are what I'd recommend, don't poke your eye out!

I took me an afternoon and a few hours after dinner to complete. A lot of time is used getting it to fit well. I wish I would have made mine a little taller, the intake/filter is on the high side and is probably still sucking in hot air that accumulates just under the hood. I was planning to make a lid for it but couldn't find a clean way to pull it off. Also didn't want it rubbing the underside of the hood.

2-8-2013

one of my buddies that did an engine swap on his Toyota Tercel, yeh he dropped a turbo engine in it - dude is crazy, anyway he suggested I add this video...

I had some exhaust leaks. I seafoamed my bugeye to find them. The smoke doesn't show up so good on camera but this really helped me track down the bad gaskets.

Seafoam - YouTube

2-15-2013

hands smell of grease and coolant.. and lava soap...

Got my PNP/rebuilt turbo installed tonight. Wrapped most of my up-pipe too, it has one of those flex joints on it.

Installing the new-ish turbo resolved some exhaust leakage too. Her rumble sounds even sweeter now.

98 more miles of break in on the turbo then its GAME ON!

here's some pics of the practice PNP I did on a questionable TD04, I did a slightly better PNP job on the one I installed. Practice makes perfect.

photo's note- I was using an LED flashlight to shine down in the cavities of the hotside and broke out the flash and all that for the compressor, that's why the lighting looks all weird.

Next time I'll set up the flash(es?) from the start.

These pics are the newds of the TD04 I took to the first DFH meat. I'm bringing the second one I did for show and tell, just will be a little harder to see...