Interested...

Old motor out... 

 
New Motor Build... well it's the old one with a... facelift...

 
Yes... that's an intake manifold in my boot...

What happens when you can't get 4" mandrel aluminum easily... pie cuts and my hand was "just" small enough to linish the inside all smooth like after welding... If I get particularly adventurous one day it might get redone in CF.

Nothing to see down there... but it is sealed from the engine bay...

it's all in there... mwahahaha

I swear that downpipe was less... "bronzey" in the previous piccy... Gotta get that bit ceramic coated still...

First time the boot has been used since I've had this car!

 
 
 
 

Phew! That's a lot of effort much props! One thing I don't miss working on the 2 is limited space in the engine bay

In all honesty i hated that a bit, but that's the thing about modifying... if you don't like something... change it... with the setup the way it is, probably the worst thing to access is the back of the water/air intercooler now... that's a PITA but otherwise everything has been made more accessible... turbo drain hose? no worries. Alternator now a 15 min affair... prob about 30 going back in cause I get all OCD on getting torques right lol.

Howd you support the intake pipe pre turbo?

Made up a plate that goes under the inter-cooler which supports the pipe near the filter... It was rigid in there without it but definitely solid now... also the only pipe in that part of the engine bay is the fuel filler pipe... wasn't brave enough to re-route that sucker lol.

Cant wait to see your thoughts on the EFR, I would like to go with an EFR on mine one day as I think it should be a very responsive turbo as well as being very capable of producing good numbers.

Looks like a crazy build. Well done!
Are you going to fit a stainless oil return line? I would recommend as the braided line will fail.
 

Yup, made up a drain pipe... the way the manifold sat when the hose was dummied up I wasn't happy with how it would drain so opted to use pipe instead so that it was always going downhill, couldn't do that with the hose.
 
Actually had to redo a fair bit due to that manifold as it wanted to foul on everything haha, dipstick tube, drain pipe, oil cooler fittings, even the oil/coolant bypass initially fouled... but got there in the end and then heatshielded everything for good measure... so yep... that was fun making a custom dipstick tube and dipstick lol

Ah yes, brings back a few memories of a similar path of modifications to my 3STGE. I blew the oil return line at the MR2 Trackday Challenge 2013. The car was (supposedly) tuned and run in. During the run it, the manifold heated the oil return line until it turned it into a brittle plastic 'like' hose encased in the braided line (Earls line). I did a few laps then the oil just went everywhere causing a lot of smoke but no fire. After that, I had a bunch of modification to the thermostat housing, dip stick and oil line to resolve the issue. After that, there were issues with turbo mounting studs coming loose. Turns out the way Ric Shaw solves this for his RX7 which ran in Nurburgring 24hr was a Inconel gasket for the exhaust manifold on the turbo and Inconel studs as both components did not suffer stretching or blow out (my stainless steel gaskets blew out like paper during the Wakefield 300). If you are running V Band, you will be fine.
What power are you expecting to see? I know a few guys with similar set ups are getting around the 300rwkw mark. These guys were at MTC. While I was releasing the cars for the Hillclimb (great job!) you could see exactly how the cars deliver the power. The bigger hp cars certainly had a degree of lag before they would light up the wheels when they came on boost (pretty good sight to see). It did effect the times of the cars as they had to wait for the power to arrive. Is that an issue for you? Is the car a road warrior or a trackday weapon or a bit of both?