Turbo Upgrade questions...

[tpunx99GSX]

Ok I just want to clerify this with everyone to get the best method of going about this upgrade.
Current mods on car:
RRE 6Bolt block
2g Pistons
Stage 2 2g head
680cc injectors
16g turbo
Fidenza Flywheel
ACT2100 Clutch
Forge MBC
DSMLink
3/S Fuel Pump
3" Turboback exhaust
Intake filter and tube


OK here is what i need to clearify. Soon I am putting on my PTE 50 trim, FMIC, Ported Exhaust Mani, and Tial Wastegate. When i first did this upgrade on the Red GSX it took many trips to Home Depot and it just seemed like a total bitch to install this turbo. Well its now time to put this bitch on the GST.
First Questions: What is the best way to plug the coolent lines going to the turbo? The one coming from the block was a total bitch to find something that would be flush enough for the turbo to fit properly. Is there any trick to this? Does anyone know the exact threading that will work for a plug?
Second questions: The water pipe that goes along the block will likely need to be dented to allow room for the bigger compressor houseing, is there any way around this? Is there any negative effects associated with denting this pipe?
Third Questions: Is there any other tricks that anyone can think of to make this process less of a bitch then the last time i did this?
I am totally dreading this install, every turbo install i have ever done (~7 turbos) has been much easier then this one. But yet i am really excited to get this baby on. I am just not going to rush into this one like i did when it got installed on the GSX.
Thanks in advance for all the help,
Tom

[slowbubblecar]

For the water lines, you can just cut the fittings for the banjo bolt off the water pipe side and use tubing to just connect that side to the other water line side on the thermostat housing.

For the turbo install, a way to get around denting the water line is to install longer exhaust manifold studs and get a spacer plate for the manifold. The spacer plate is just an exhaust manifold flange to put between the manifold and head. It can be kind of a PITA to take the studs out of your head sometimes but it is better than denting the water pipe.

[tpunx99GSX]

For the water lines the actual problem i had was that the turbo was hitting the nut on the banjo bolt, so it wouldnt fit properly. Really wierd being that ive never heard that you need a slimmer bolt for that. On the GSX i ended up going to home depot and just trying a bunch of shit, ended up cross threading one of the plugs but it did the job, just dont want to screw up this block though.

[slowbubblecar]

Is the turbo water cooled? I was thinking you didn't need to use the water lines that is why I said you could just loop them. I have never had a problem with getting the water line bolt in a turbo.

[tpunx99GSX]

The 16g that is on my car now is water cooled, the PTE 50 trim that is going on the car is not. So the bolts need to be blocked off.
All i know is that one of the biggest PAIN in the ASS of the whole install was that stupid banjo bolt that was on the block of the engine getting in the way.

[slowbubblecar]

What I would do is talk the turbo feed line off on the thermostat housing side and cut the banjo bolt fitting off on the other side on the water pipe. Then, I would just use some tubing and hose clamps to loop the rest of the turbo line on the water pipe to the spot it went on the thermostat housing.