The Official CASPERAMC turbo progress thread

Do you have a project going or will you be starting a project here very soon and just want to keep a log of everything you and when? Share with everyone every step of the way what sort of progress you are making on your project.
CASPERAMC
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The Official CASPERAMC turbo progress thread

Post by CASPERAMC » Tue Jan 08, 2008 8:26 pm

1-7-08: it was a really nice monday today, much hotter than usual (50s) in NJ and i started my turbo project.
-So far today, gave up on having the turbo water cooled, so it will just be oil cooled. Oh well, i'm sure it will not lose sleep over it.
-I took off the oil pan and brought it to the place to have a nice aluminum pipe welded on. the only problem is that the pipe that i had that i was told was aluminum was actually steel so the welding guy is gonna see what he can do.
-Took off front fascia and cut holes for the intercooler (it was fun).
-Took out ECU and found a place to mount it, now i need to actually do that. Maybe tomorrow. It will be in front of the battery under the intake.
-Ghetto-rigged a new coolant overflow bottle. i couldn't find an aftermarket one what would fit the small space that i had, and i wasn't goingto spend the money on a new srt overflow bottle even if it would fit. Mine's super duper cool anyway because i made it out of a coffee mug LOL.
-Took off rear section of the exhaust
-Got a booboo
-Didn't break anything yet (that i know of) (knock on wood)....dont worry I will.

And now onto the pics:

A shot of teh engine bay
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Cutouts for the intercooler Left and Right:
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My new favorite tool that i used to cut the holes:

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Another of my favorite tools that i will probably use a lot:

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The oil pan covered in bags for safety :) :

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Yay air compresser:
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Fcuk flats at 70:

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My booboo (its there just look close)...there was even blood:

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Post by CASPERAMC » Tue Jan 08, 2008 8:47 pm

1-8-08: Another beautiful day in NJ. it was in teh 60s today. Ok today i:
-Fixed the holes for my intercooler so it sits even.
-"modified the intercooler" since i have an automatic transmission, there is not much room for intercooler piping, so i had to cut off the notch on the intercooler that stopped the tube from going any further so that i could shove it on all the way. it will sit on my transmission, but im pretty sure it will fit.
-successfully moved the ECU. this one took up a lot more time than i anticipated. i had to cut and lengthen a lot of wires so that the plugs could reach the ECU in an acceptable place. i'm happy with the placement. it looks clean...ish. i may make a box for it at some time, but i am happy at the moment with it. i had to cut the original bracket to work with where i wanted it, but it ended up working out well.
-plugged the coolant holes on the turbo so nothing gets in there. i just put some silicone on the holes in the original bolts for it and screwed them in.
-started taking off the rest of my exhaust. i tried to take the midpipe out, but there wasnt enough room to take it all the way off (i needed like 2 more mm) so i went to take the cat off. got 3 nuts and then the third is stripped because i didnt realize i was using a 12 pointed star socket. started to take the header off instead. i took off the bolts for the upper heat shield and snapped one, but thats ok because i dont need it anyway. but now its stuck in my 8mm socket and i really like that one. i tried yelling at it, spitting at it, stabbing it, i even hit it, and it won't come out. ill try again tomorrow.
-Tested my coolant overflow bottle with hot water and no leaks!!!! Ghetto FTMFW!!!!!
-got another booboo


i'm still waiting on my oil pan, ill have to call the guy tomorrow

and now onto the pics:


I put my intercooler on today and noticed that it was crooked:

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So after some cutting, i fixed it. sorry for the shitty pic, but i had to hold it up while taking the picture:

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New ECU location:

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Doesn't get in the way of my 3" AGP Intake:

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Plugged coolant holes:

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I really like that socket too:

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New booboo of the day. Its on my thumb. I burnt/cut my thumb. the metal cut/burnt right through my glove and thumb. it was when i was cutting my ECU bracket. no blood because it burnt the cut:

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Got my new tires today. BFGoodrich Traction T/A for my winter tires. 195/60R15 o hells yea lol actually wider than stock, but it still seems so small:

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Hopefully more progress tomorrow
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INVUJerry
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Post by INVUJerry » Tue Jan 08, 2008 9:27 pm

You call that a boo boo!? I sliced my arm taking out my gas tank on my 95. Rust+gas+open wound = death.

Good job though! I like what you're doing. We should hang out sometime!
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Post by J-Villa » Tue Jan 08, 2008 9:28 pm

awesome! more more
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Post by INVUJerry » Tue Jan 08, 2008 9:38 pm

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So many neons so little time.

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Post by 2002TuRboNeoN » Wed Jan 09, 2008 12:15 pm

u get that bolt outta that socket yet??? put it in a vise or use vise grips and use screw driver or punch and hit it with a hammer..easiest way...or use a torch if you think your socket will last the heat and not warp...nice job on the car
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Post by CASPERAMC » Wed Jan 09, 2008 8:55 pm

1-9-08: Another beautiful day in NJ. it was supposed to rain all day, and it did for a bit in the morning, but then the sun came out and it was in the 50s. today was a good day, i:

-took all of my exhaust off. i actually had to take the header off still attached to the cat and wiggle it as far back as i could so i could get my impact gun to the nut that was half stripped, and completely rusted on. the impact gun made short work of it and it came right off.

-took off the heat shields from the header. there was an upper and lower, and then one underneith that was made out of a more maliable material that i may flatten and use on my firewall.

-took off a bracket that held the header. it was in my way, and was unneccesary anymore.

-took a hammer and knocked back some of the firewall. i wrapped a hammer in a towel and hit it lol. i know theres not a lot of room there so every cm counts

-found out that my fuel system does not stay pressurised when the car is off for a while. that cant be good. i had to move something around the fuel line and i was gonna release the pressure carefully with the schrader valve but there was nothing there, and i took the quick connect off and no pressure.

-drained coolant

-took the stock coolant overflow bottle out. it had this brownish goo in it, which can't be good lol...o well

-put vacuum lines on the turbo. 2 nipples are big and 1 is small. i have 1 size boost line...yay i have to force stuff haha

-took wastegate off. it wont fit behind the engine. i think i probably have to take the actual turbo out of the manifold to get it to fit.

-took weatherstripping off the top of engine bay. took all of 5 sec but it looks like i did more stuff lol.

-got my new modified oil pan and installed it. expensive little thing. $112 for the whole thing because they had to make a new pipe for me since the one i brought them to weld on was steel instead of aluminum, but i didnt know. they had to machine a nice little pipe for me and the kid that actually did it was someone that i went to high school with and i haven't seen him since then.

-bought more tubing that actually fits on the tube of my oil pan. its a little bigger than the one on the stock oil return line for the turbo, but some hose clamps should fix that, and i dont really have a choice. there isnt that much pressure behind it anyway.

-bought more piping for intercooler. I dont think the cold side pipe wil reach my throttle body so i got a small pipe that i can put in between hopefully. i also got a 2" elbow that i can hoefully finagle the charge pipe around my power steering cooler because that looks like a pain to move and i hope that will do the job.

-took the stock oil pressure sender off. i actually bought a special socket for it, but it wasnt long enough, so a nice vice grip did the job. it actually came out very easily.

-assembled some of my oil pressure sender holder/oil feed line for turbo contraption.

-got another booboo





and now onto the pics yay!!!





my car is taking a piss test:

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EVO O2 HOUSING FTMFW!!!!!:

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Out with the old:

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Theres some more room in there:

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I'm doing stuff right this time. little baggies with labels and everything:

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Old coolant overflow bottle:

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Even more room now:

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Vacuum lines hooked up:

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Had to take wastegate off:

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Engine bay shot with empty space:

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Modified oil pan:

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Closeup on the weld:

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And thats what an open engine looks like from the bottom:

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Yes that is a $20 torque wrench, but i havent really torqued anything:

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Some of my contraption:

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This is what it will look like:

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Oil pressure sender on the block:

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And thats what it looks like off the block:

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Wrong tool, notice how it doesnt fit:

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The right tool, it fits almost anything:

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Ready to go on the block:

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My new booboo. i pinchec my pinky and theres a little blood bubble. it gets worse and worse every day, i dont think i can take another injury lol


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and thats it for today, i hope to finish within the next few days



wish me luck

-mike[/img]
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Canada
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Post by Canada » Wed Jan 09, 2008 9:18 pm

I <3 Your Car Mike.

I also hate you. :lol:

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Post by Kevin_GP » Wed Jan 09, 2008 10:55 pm

Woah, had fun at homedepo? Thats alot of brass fittings! You don't need to keep the oil sender thing, its just a dummy light if the psi is lower than 5 psi, you should get a good oil psi gauge, its a good thing to have with a turbo motor. Other than that, it all looks good.

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Post by CASPERAMC » Wed Jan 09, 2008 10:57 pm

i have another oil pressure guage thats why there are 2 t's on the thing. and yes lots of time at home depot lol
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Post by Kevin_GP » Thu Jan 10, 2008 4:41 pm

CASPERAMC wrote:i have another oil pressure guage thats why there are 2 t's on the thing. and yes lots of time at home depot lol
Ohhh ok, well regardless you still don't need the dummy sender if you have a good gauge. An oil psi gauge has saved my motor a few times.

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Post by CASPERAMC » Thu Jan 10, 2008 7:04 pm

i dont like lights on my dash lol and i dont like pulling the bulb either haha
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Post by CASPERAMC » Thu Jan 10, 2008 9:49 pm

1-10-08: Not as nice a day here in NJ. it was in the low 50s-40s and it was very cold in my garage. The day started out ok, but then didn't end as i would have liked. I was hoping to finish today, but maybe tomorrow. Anyway, today i:

-put the IAT into the coldside pipe for my Megasquirt and sealed it

-sealed the oil return line with a hose and put 2 hose clamps just to be sure.

-put my boost line on my intake manifold. i put it in place of the pcv hose.

-put my oil contraption on

-took my oil contraption off

-switched the positions of the 2 ends on the contraption

-put it back on

-took it off again

-switched the positions back

-put it back on

-moved my extra coil pack and injectors that fool the computer so i don't get a CEL to a place where you can't see it. that took a while because one of the wires came off so i had to resolder it and then drill a hole with a bit that didn't want to go through. i like the new position though.

-ran the wires for my fuel and oil pressure guages. the oil pressure guage is going in now, but the fuel is later. i ran the wire anyway so i wouldn't have to do it later.

-took the turbo off the manifold. it didnt want to come off, but i got it.

-heat wrapped the lines on the firewall

-modified the manifold adapter plate so that it actually fit. that was a pain because i kept having to put it on and take it off when it didnt fit. i had to cut off a corner where there was supposed to be a bolt for the srt-4 manifold, but the bolt wouldnt fit anyway, and it was hitting my alternator, so i just got rid of it. weight reduction FTW!!

-installed the manifold adapter plate. allen screws are annoying

-put manifold on

-put in turbo and put clamp on it.

-realized that my oil contraption isnt long enough :(

-no booboos today i just kept opening all of the old ones.



picture time:





IAT in cold side pipe:

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Oil return line with hose:

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This is what my guage came with to wire the whole thing up...almost enough wire to go down my pillar lol but not quite enough for anything at all:

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First time the contraption is on i ended up switching the oil pressure sender to the end, but it may change again:

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Boost line coming from intake manifold:

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And thats where the magic happens...small chip i just noticed though :( :

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And there it is just sitting there looking pretty:

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Heat wrap and stainless steel zip ties...cost a pretty penny:

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Snug little brake lines:

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No code fixer new location from the bottom:

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From the top:

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Manifold adapter plate srt-4 side:

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Wayy better 2.0 side:

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Manifold on:

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A look at the manifold and adapter plate:

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And thats all teh pictures i have today, sorry i didnt take one with the turbo on there for you guys. ill have one tomorrow. doesnt look like ill have too much room for my intake, ill have to turn my battery sideways and my next project is getting it to the trunk. tomorrow i need to go to home depot to get some more brass fittings for my contraption. maye ill add some zig zags so the oil wont flow at all. anyway, i am shooting to be done tomorrow. cross your fingers





-mike
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Post by kc2005ptgt » Fri Jan 11, 2008 3:30 pm

Yay! nice job... hope it all turns out well for ya!
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Post by CASPERAMC » Sat Jan 12, 2008 11:56 am

1-10-08: Crappy day. it rained and it was cold and i broke stuff. noting worked out for me and when im done and try to start it, the engine will probably piss oil everywhere...anyway i:
-broke my radiator cap holder thingy. i forgot the name for it, but it was putting a hose on it that was too big and i tightened the hose clamp too much and it snapped. i ended up drilling a big hole and putting a barb on it that is the right size and i sealed it. hopefully it will hold
-finished putting my oil feed line contraption. i dont think its on tight enough, but it was the only way i could fit it, maybe ill get lucky and there will be no oil everywhere, but i doubt it
-put the oil return line on. i had to cut the sstock pipe becasue it was too long, and then i put a hose going into my oil pan.
-put all of the rest of the bolts for the manifol on and tightened them
-put the wastegate on
-put my battery sideways. theres no room in there, next project is putting it in the trunk
-put half of my intake in. wayyy too big lol. 3" is too wide for such a small place, but i shoved it in there. i also put the pcv line on that, which didnt want to fit, but i made it. i force things a lot lol
-modified srt-4 charge pipe to fit. i had to cut it and put a coupling on, but it fits. its a little too close for comfort to my axle though, its about a half inch or maybe less from it.
-tried to put my intercooler on, but wouldnt fit on the cold side. i have to modify the intercooler to make it fit. and by modify i mean cut it

i think thats all i did, i may have left something out, but im pretty sure i got it all. maybe ill finish tomorrow...maybe not


picture time!!!


This is what happens when you force things:

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Fixed hopefully before i seal it:

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Random shots from oil lines from bottom:

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Better shots:

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What the engine looked like at the end of the day:

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Part of teh intake on:

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Cold side pipe doesnt reach lol yay what a suprise:

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As far as the intercooler goes in without modification:

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This keeps be going:

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no more pics. mabe a better day tomorrow

-mike
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Post by own3d5974 » Sat Jan 12, 2008 1:39 pm

i hate you.........your living my dream :D
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Post by CASPERAMC » Sun Jan 13, 2008 5:22 pm

1-13-08: CAR IS UP AND RUNNING YAYYYY!!!!! unfortunatly i cant drive it anywhere :( i cracked my thermostat housing and antifreeze is everywhere and smoking. o well thats a "minor" problem and an "easy" fix. anyway, there is a clicking noise that i dont know what it is. i took a video. it happens when i start to give it a little gas. what do you guys think?





video:



http://videos.streetfire.net/video/df89 ... 1fcc54.htm
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INVUJerry
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Post by INVUJerry » Sun Jan 13, 2008 6:44 pm

I donno, sounds like you're mis-firing a little.
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Post by AgentV3 » Sun Jan 13, 2008 9:27 pm

I'm putting my money on an exhaust leak, likely somewhere on the manifold.

I have a buddy with a first gen Neon that attempted to replace his EGR valve and didn't get it seated all the way, sounded exactly like that.
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Post by atom » Mon Jan 14, 2008 5:21 pm

check belts? the intake of that thing sounds sweet! what are you going to do for exhaust?
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Post by CASPERAMC » Mon Jan 14, 2008 5:29 pm

im pretty sure its an exhaust leak at the gasket. i used a weird metal gasket. not entirely sure why...actually i do it was given to me haha. maybe i need to tighten the manifold with it hot to have the gasket seat well.


for exhaust i have my stock midpipe and srt rear end. ill probably keep that for a while, but eventually i would like to get a cutout and a really quiet exhaust. i like the sound, but it gets droning sometimes
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Post by SOHCKing03 » Mon Jan 14, 2008 7:29 pm

Can you post up a parts list?

Also, maybe I didn't catch this somewhere, but how are you tuning this?

-Brad

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Post by INVUJerry » Mon Jan 14, 2008 7:53 pm

CASPERAMC wrote:im pretty sure its an exhaust leak at the gasket. i used a weird metal gasket. not entirely sure why...actually i do it was given to me haha. maybe i need to tighten the manifold with it hot to have the gasket seat well.


for exhaust i have my stock midpipe and srt rear end. ill probably keep that for a while, but eventually i would like to get a cutout and a really quiet exhaust. i like the sound, but it gets droning sometimes
With a turbo, it'll be lots quieter. Don't try to tighten the gasket while its hot. Go to the dealer and get Mopar gaskets.
SOHCKing03 wrote:Can you post up a parts list?

Also, maybe I didn't catch this somewhere, but how are you tuning this?

-Brad
He's using MS for tuning. Parts list can be found in Forced Induction forum.
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Post by CASPERAMC » Mon Jan 14, 2008 8:27 pm

invujerry wrote:With a turbo, it'll be lots quieter. Don't try to tighten the gasket while its hot. Go to the dealer and get Mopar gaskets.

yea i will see how it is with the turbo. the only problem with the gasket is that i might have to take everything off to replace the gasket. it was stupid not to use the right one to begin with, but maybe i have a loose bolt ill check that before i do anything
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Post by Canada » Thu Feb 07, 2008 9:17 pm

No updates.

Update or :ban: :lol:

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Post by CASPERAMC » Thu Feb 07, 2008 9:24 pm

lol update is that the car is sitting in my driveway with a blown headgasket and im away at school...but i do have some really bad news. im fixing the car, turning it completely back to stock, selling all of the parts and the car :(
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Post by KrackstaR » Thu Feb 07, 2008 9:54 pm

rims sell much?
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Post by lvlistchif » Thu Feb 07, 2008 9:56 pm

damn wtf howd you blow the head gasket? to much boost?
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Post by Canada » Fri Feb 08, 2008 5:08 pm

CASPERAMC wrote:lol update is that the car is sitting in my driveway with a blown headgasket and im away at school...but i do have some really bad news. im fixing the car, turning it completely back to stock, selling all of the parts and the car :(
Definitely not the kind of update I wanted... :banghead:

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Post by CASPERAMC » Tue Feb 26, 2008 12:32 am

yea i know not theupdate i wanted either. and i may sell the rims depending. if i do though, it will be at least a grand for them because they cost me double that
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