Alright, I'm starting this thread because I keep running into questions. When I find new questions, I'll just reply in this thread.
Here is what I've done so far. Both manifolds are bolted down. Turbo is also bolted down. Swingvalve is in place, not torqued. To make the manifold fit I did the following. I slotted the header flange for expansion per Chris' recommendations. I had to grind/sand down the 3rd/4th cylinder intake runners so I could install the wastegate actuator. I also created extra clearance to avoid a stuck open wastegate. I had to start all bottom nuts on the exhaust studs before full pushing down on the manifold. I had a problem torquing down the lower bolt on the 4th cylinder.
Now I'm at the coolant lines. I have a set of TU coolant/oil lines. When I put the top coolant line on, it is way too long. There is the adjustment in between the two sections, but it isn't enough. I also have an interference problem with the wastegate actuator. Oil line doesn't seem to be a problem. I just need to get an isolated clamp for that.
I haven't tackled the lower coolant line. Last year I called Chris to order the small parts my manifold didn't come with. That included the oil drain and an extra section to extend the length of that line. With the extra length adapter, I'm concerned about vibration and durability. I'd like to add back some sort of support for the coolant line.
What have you guys done to make these lines fit? I was thinking of getting a longer adapter for the turbo to raise the coolant line up over the wastegate. I was either thinking of having a shop make up a shorter braided line or cut and flare the section with the adjustment.
My other questions are about the turbo support bracket. How does that work now? Do I just move the lower mounting point to the left nut on the engine support bracket? Also, what are the torque specs on the swingvalve nuts? What should I expect with the exhaust? I know chris says there is enough length, but..... I have some 1in header wrap and ties given to me as a gift. What should I expect to wrap? I already protect all the oil/coolant lines and electrical lines on the back side of the motor. Should I order up some sleeves to protect the shift cables?
I still hope to get this car running by the end of the month. I really miss going topless and smoking the unsuspecting. I have a whole bunch of new kids in town to teach lessons to. Plus I hate working on cars in the freezing cold.
Later
James