GEN 1 Twin Turbo 6.2 Raptor build: DIY Tri-Y turbo headers

Hand formed intercooler end tanks out of 0.0625" ... 5083 aluminum? I forget.
It held plenty of pressure in the STI with the 750hp garrett core that I built. Ran 33psi of boost on that out of an EFR 8374 (79lb/min or ~790hp)



4 inch outlet. Trimmed it a bit after. I wanted minimum volume while keeping efficient flow (based on eyeballing a ton of optimized intercooler end tanks from formula 1, and other CFD simulation images on the internet)



Spent some time with a die grinder after welding to smooth the outlet towards a mini velocity stack type config.



Finished product with 2 3" inlets and 1 4" outlet:


After the intercooler I pre-fabbed the Y pipe for underneith using solar flux. Worked pretty good. Feels nice not using a ton of argon... shit is expensive nowadays.




Here is the final config and some of the last pictures I took since a week or two ago.


Got some matte black/reflective blue graphics from josh @ rappygraphics


---------- Post added at 09:42 PM ---------- Previous post was at 09:40 PM ----------

CineSLR said:

You sir are an inspiration. Keep up the good work. I hope it goes smoothly!

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Click to expand...

Ha thanks. It's been kind of a *********** but I'm really happy I got the hardest part done. The downpipes and Y pipe will be easy since I got a pipe expander and can just do short slip fits with solar flux.

Did a pre scaling of the 4" maf.

Did some calculations and nailed it from 0 - 40lb/min in 1.5 hours and 3 reflashes
Goes in this week after ford puts the warrantied control arm in.

Awesome man. I can't wait to see videos of this thing up and running

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did you buy a motor to have for external mockup? or have you been pulling your motor out every time you want to mock up/fab

I got a spare longblock for mockup. Lol

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...And I thought MY build was out there!!! LOL

CHEERS!!!!!

You know, I heard you can get a raptor with factory turbos now. Might be easier?

Sweet project - impressive fab. Will you keep stock internals?

I like my V8 lol. Factory for now i don't see a need for over 600whp .

Probably call it done for now and keep around 550 whp at around 7 psi to keep it reliable.

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---------- Post added at 03:17 PM ---------- Previous post was at 03:14 PM ----------

Used like 5 1/16 filler rods and 4 1/8 filler rods to build these up enough to drill and tap with 3/8 npt for a 316 SS barbed fitting for oil drain.



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---------- Post added at 03:19 PM ---------- Previous post was at 03:17 PM ----------

Here's to a N/A intercooled motor [emoji48]

Scaling the maf was very easy with some inputted math functions in hptuners.





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why didn't you just use a weld on fitting? not picking on your choice just curious

Darthyota said:

why didn't you just use a weld on fitting? not picking on your choice just curious

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I did fittings instead of welding a pipe on in case it gets dinged it can be replaced. Aluminum is soft