On3 96 Cobra 8475 Gen2 Ff turbo install

BigBore96 · Sep 18, 2019

Figured id go ahead and post some pictures as the install progresses. A little back story on the car.

Short summary
Boss Block
Custom dss pistons
Stock cobra crank with forged rods etc.
Custom Turbo cams speccd by Todd.
Built T45 from t45source (Time to test its limits)
Termi IRS w/ftb bushing kit
I am using a UPR k member on this car currently.

Old setup is alrdy off aka longtubes. Draining coolant and removing all that and going to continue the turbo header install.

Passenger side header is installed. It's a bit of a pain. Issue 1 is the 3rd from the front bottom bolt needs to be a stud. So I had to take a stock stud and cut it down, thread it in and oddly enough that wasnt good enough either for an easy install. Had to lower the k member from the engine to get the header onto the stud. I then got it all tightened down to realize the k member bolt now interferes with the header so I had to trim part of the washer off.

white95 · Sep 18, 2019

...and so it begins! Good luck and keep us posted.

BigBore96 · Sep 18, 2019

Got the drivers side header bolted on. I took this picture before mounting the k member so you all could see clearance of the oil relocation kit. I'm using the billet one which doesnt come with the kit if I remember correctly. I have been running this oil relocation for a couple years now. No issues at all. I do think I'm going to put a heat protective sleeve on the hose prior to reinstalling it as it's pretty close as you can see. Ignore the seeping coolant. It's just slowly dripping into a pan. Also ignore the k member. It's a UPR that's been on the car for years and I havent repainted or done anything to it so it's about the only ugly thing left. Paint for the car is this winter.

Also for those wondering. Aside from upgrading the turbo and having on3 weld on the maf flange I'm using the kit as it came and will change what I need to later if need be. Again the turbo upgrade is their 84mm ceramic wheel turbo. Injectors are 80lb high impedance and the maf is a slot style BA5000. I will be doing the tuning myself with the SCT PRP as always.

Time to remount the k member then hit side.

A question for you guys. Have any of you ever mounted the radiator forward such as within the core support? I've got a aftermarket radiator and of course it's much thicker so I think I'm going to have to do something for sure.

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BigBore96 · Sep 18, 2019

Test fitting the hot side piping. V bands seem pretty well made.

Abs unit is in the way. Need to figure something out with that. Truthfully I need to delete it as it doesnt work. 96 body with 98 harnesses. Doesnt connect.

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ttocs · Sep 18, 2019

its not too hard to move the rad up a little more if your crafty.

BigBore96 · Sep 18, 2019

Last one for the night. Turbo test fit. Ignore the turbo clock. Definitely is tight in there as expected. My radiator I think I can get away with. Having a puller fan I dont know if I could swing that without moving it forward. So I need to decide move it forward and try or just get some pusher fans ( they told me up front I'd probably need to do this). Anyway. Pics below. Downpipe is attached in one. I also eyeballed the downpipe attachment to bend under the car and it appears to be a good fit as well.

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evilcw311 · Sep 19, 2019

If you like having to replace your belts all the time I’d say your good to go. If not, invest in a heat blanket for that!!!!!

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98snakehorse · Sep 19, 2019

Very cool. Let me know what you think of the On3 stuff. Have a look at my build thread, I moved my Rad and fan forward almost 3 inches and made my own core support.

lwarrior1016 · Sep 19, 2019

Awesome!

For the abs, you can get a delete block or just get some new line and bend it and flare it. Brake lines are super easy.

You can also get rid of that a/c idler puller by getting a shorter belt and using a grooved idler in place of your smooth one.

BigBore96 · Sep 19, 2019

Thanks guys. I'll keep yall posted just woke up from a long overdue sleep in session on our new bed she wanted since I got the turbo. I'll be heading to the garage after lunch and mocking up the rest to see any fitment issues before I start sealing it all down.

I will be installing a turbo blanket for sure. And I'll definitely be looking into my options on the radiator and abs system. Abs I'll probably flare and relocate it for now as I dont want to wait and find a delete block. It seems the 4 channel delete blocks are readily available but not the 3 channel.

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ttocs · Sep 19, 2019

if your abs pump is like mine on my 94 its not hard at all to flip the pump and put it on the inside of the frame rail. That will make space for under the hood but you might check that it would not be in the way of any of the other plumbing to go in.

BigBore96 · Sep 19, 2019

ttocs said:
if your abs pump is like mine on my 94 its not hard at all to flip the pump and put it on the inside of the frame rail. That will make space for under the hood but you might check that it would not be in the way of any of the other plumbing to go in.

Thank you I'll check. The 94 through 97 r 3 channel so they're the same iirc. My plan is to get the kit fully installed and see what I need to do afterwards. It's in the way of 1 Watergate which shouldn't be an issue to remove and figure out the abs if needed

I'll post pics tomorrow. I moved the radiator forward but fan is still too big but I can now get a slim fan as a puller instead of doing a pusher.

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ttocs · Sep 20, 2019

no intercooler?

BigBore96 · Sep 20, 2019

Its intercooled. Havent mounted it yet but it's in the front. Really the only thing up there is the power steering cooler line.

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ttocs · Sep 20, 2019

they make a push fan that will go between the cooler/rad?

BigBore96 · Sep 20, 2019

With the radiator in stock location it would be possible. Since I moved it forward it is not.

Got the wastrgates installed. Still need to run vacuum. Working on the intercooler mounts right now.

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ttocs · Sep 20, 2019

I think the wastegate will be in the way of the idea of flipping the abs pump.

BigBore96 · Sep 20, 2019

I believe you are correct. Not going to even try.

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01yellercobra · Sep 20, 2019

I'm a fan of Boss block builds. I always wondered what my last set up would be like with a turbo. Now I'll know.

BigBore96 · Sep 20, 2019

01yellercobra said:
I'm a fan of Boss block builds. I always wondered what my last set up would be like with a turbo. Now I'll know.

I love the boss block. But It's been sooo many years in the making for this turbo build due to life. This is the second version of this boss block. Few years ago v1 sucked up water and cracked a cylinder wall, ruined 1 piston, and messed up my old b heads.

It took me a while to get motivated to fix it but it now has better pistons and termi heads.

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