Opel GT

http://forums.pelicanparts.com/uploa...1129230697.jpg

Well you would obviously have to remove the hood and carefully position it over the padded form block. I have made bumps in aluminum airplane parts using this technique. An oval style may even be possible if you made an oval hardwood plug to match a
female form block.

You might be amazed if you saw some of the odd homemade tools used by expert metal shapers! (BTW, I am far from an expert, but I have formed some nice airplane parts using hammers, form blocks, fluting pliers, shrinker/stretchers and bead rollers etc etc)

Try a small proto type in a scrap pc of sheet metal. Drill a 1" hole in a block of wood, place a pc of sheet metal over it, place a golf ball sized hard round object over that and give it a whack with a BFH and see what happens.

Trying to think what I could use besides a bowling ball, I don't have one laying around.

Here's an awesome forum for that kind of stuff: http://www.allshops.org/

Try a bubble like the Buick grand national had. Just a thought

Here are a few pics of the adapter with the turbo. Yeah, she's sittin a little high.

http://forums.pelicanparts.com/uploa...1129290462.jpg

http://forums.pelicanparts.com/uploa...1129290499.jpg [img]

http://forums.pelicanparts.com/uploads6/DSCN03561129290516.jpg[/img]

http://forums.pelicanparts.com/uploa...1129290534.jpg

Terry, it is kind of hard to tell in the picture, but it looks like you have room to tilt that turbo out toward the shock tower. It seems you would just need to make a couple of flanges and weld in a short bent pc of tubing and your protrusion problem would be cleanly solved. If you have a drill press, hole saw and have or know someone with a welder, you should be able to do this.
Here are a couple of pics from my DIY 1 to 2 out muffler mod I did awhile back for inspiration.

http://forums.pelicanparts.com/uploa...1129294307.jpg http://forums.pelicanparts.com/uploa...1129294328.jpg

The problem is the flange that connects to the mani is a pretty complicated design. They dont sell them and it would be a bi tch to cut out of 1/4" plate. I think I've gotten to far to go back to redesigning the adapter. Plus, this design will allow for a much bigger turbo in the future (housing won't touch the head). And I'm.......lazy.

Here is what the stock flange I used for the adapter looks like:

http://forums.pelicanparts.com/uploa...1129295109.jpg

Not the easiest thing to recreate, atleast with the tools I have.

Well Terry, I dont know what to tell you. If you lived closer and you brought the beer, I would be glad to help you fab one up.

I doubt the perimeter shape matters much and each oval port could be closely approximated with two small hole saws and a larger one in the middle (cut each hole 90% thru then finish them the rest of the way and blend the transitions with a file/die grinder).

I have cnc machines available at work, but I myself would still just probably fab one up using old school techniques at home as I hate to ask the machinists at work for too many favors.

I appreciate the offer. If I had a CNC machine, aahhhh, the possibilities. Hard part about that piece is there is a little lip that the tubing seats into. I would need a lathe and some skills to make that.

I wonder if they will let me AutoX without a hood.....somehow I doubt it although I dont see it in our rules.

All the intercooler tubing, couplers and oil lines are on the way so this should be running by the end of the month. I'm so tempted to Megasquirt it instead of the FMU but I'll wait and see how she runs.

I will be interested in hearing how it works out, I often contemplate turboing (is that a word?) my 911 SC and maybe even my 924 (just for yucks). I know the SC's stock fuel delivery system will work with a low boost system, but the 924 would need more fuel than the stock system will deliver (aux fuel enrichment ie: 5th injector comes to mind).

Good luck and just cut a hole in the hood and worry about a scoop or bump made of fiberglass or metal later.

Yup! We need to see a pic of the completed project....:)

You could always try nature's way....

http://forums.pelicanparts.com/uploa...1129310961.jpg