Made a mock up out of polystyrene of the radiator and fan to go in the front corner. As always don't fancy drilling holes in the car so there will be a piece of aluminum bolted down using factory tapped holes.
The radiator will then be bolted to it but on rubber isolators.


All cleared  , plastic , bumper and moving arm of the pop up light.

I might have enough room for the bigger pump but only can be 100% sure when i take off the bumper

Back on the engine , all line up
 
Just a final check that everything lines up. All AOK
Inlet line clears intercooler and knock sender and brackets

Inlet lines all line up



Now ill get it all welded up, check one more time and all the parts are ready to be powder coated.
Time to prepare my car to have the engine dropped , maybe in 2 weeks time

So i went to see Plazmaman ( intercooler guys ) with my peices to be welded. They said it will be a week at least to go thru the process , welding cool down , pressure test etc. He was truly amazed and has never ever seen air end tanks milled :)
Anyway on to other parts.
Well i had the end water tanks for the second heat exchanger milled. Here you go.
 
Just to explain, 3 nipples. One and two are water in and out. The other one is for the connection to the windscreen water bottle funnel. The 4th opening is for a valve to bleed air out. Thought ild put a tapped thread on one side for a bracket to hold the nozzle for the water spray
Here is the side connecting to the frame of the car. 4 isolating rubbers to allow movement

This is the exit side for the water to travel to the first HE and the bleeding valve

This is the entry side with the inlet at the bottom and the filler nipple

Intercooler all welded up.
 
Final test fit today.
Cut my hoses to lenght and now its all apart with all the pieces heading of to the powder coaters

Also received my second HE for the A/W inter cooler
Boy PWR does some great welding :) They also coated it black for me.

And many thanks to Josh at CRW for getting me the Spal fan :) FAST RELIABLE AND THE BEST MATE

From the front you can see the exit line at the top. The inlet is to the side. Half way up it the inlet to the Funnel of the windscreen washer bottle. And on the corner is the bleeding valve
Also on the front is a tapped thread to hold the bracket for the water spray nozzle which i need to add

The Spal fans are great being water proof but the wiring plug isn't , so ill change it to the same Toyota plugs that are used for the engine bay fan.
This second HE was added so as to get better cooling when at idle and more cooling surface area

Lots of powder coating
 
And received the parts i sent to powder coat :)
The Coolant over flow reservoir bracket

The outlet to the Rotrex


The air inlet to the Rotrex

The Inter cooler/engine bracket mount

A plate that i made so as to mount the second HE of the A/W inter cooler

and the Inter cooler

Put the 2nd HE in place for the test fit and all AOK clears everything

You can see the end of the filler neck that will join up with the HE

Should get the new hoses this week and this section finished

Here we go.
Rotrex bracket on the engine

Heads up the engine is N/A design but has all the necessary threads on the block to add the Turbo gear. Point you need to add some items. See to the left of the bracket the 2 locating pins need to be added for the axle bearing carrier.
Here showing the EMF filter and the wide band Knock sender
 
Brackets for the Turbo axle added

Making sure the copper washers are added. Those who have followed my thread will know why i am so paranoid about them.
 
Rotrex bolted on

Next the inlet to the Rotrex

And the Inter cooler

Connected the water in/out to the inter cooler and the custom bent aluminum pipes so as to go around the engine better with no chance of them touching the engine or bending

As you know i have a WG being installed.
Since i machined the end tank of the inter cooler where it will be located and on the cold side, i machined the matting surface to embed an o-ring to guarantee a seal.

Waste Gate and BOV added

Nice big 38 mm bypass hose for off throttle pressure release

So now i have to finish the wiring loom as it has to be added before i can put the Inlet Manifold on

Back on the Inter cooler water line.
This is the cut funnel from the OEM wash bottle. Issue was the rubber grommet wasn't good as it just pushes up against the body. I needed a grommet that would be tight on the funnel at the same time have a slice thru it that half would be on the panel and half under the panel hence securing it.
Well had a few harnesses lying around and the grommet of the frunk wiring was ideal :)

And from underneath

On the funnel there is a 8 mm thread which ill be adding a nipple that line will go to a Celica GT4 expansion bottle with a breather. Its small , looks OEM which it is and i have one laying around. This way the system will never be positive pressure or vacuum