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Performance Modifications for the NG900 / Old 9-3 This forum contains PERFORMANCE related Q&A's for the NG900 and 9-3. This may also include suspension.

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Old 08-29-2007, 03:00 PM   #1
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New intake/ exhaust mani

I'm just putting this out there, I havent done it yet but i intend to thoroughly work over the top end of my 95 900 SEt over the shitty wisconsin winter, if i can get it in my damned garage. That's another story, anyhow here are my ideas.

I want to build an intake manifold out of 6061-T6 aluminum that would re-locate the throttle body to the passenger side of the engine compartment to make use of the hole in the wheel well for charge pipe routing. The reason for this mod is i want a high flowing intake design that would eliminate the stock design. Along with that go the ideas for my new turbo manifold.

The new turbo manifold i want to build out of stainless steel with 1 5/8" primaries or maybe even 2" primaries to go into a T3/T4 .57 trim or .63 trim, I'm favoring the smaller version for spool time. That being said I also plan to relocate the battery to the trunk, off set the turbo towards the drivers side to make room for a 3.5" down pipe coming off the left side of the turbo instead of the right side (engine bay view) and run the new intake pipe over to where the battery used to sit.

Being that I have never done this before, or anyone else to my knowledge, with the exception of perhaps Trollspeed, I'd like to hear some constructive criticism. I'm aware that not many people do crazy and different things like this but i have no issues being completely different. I also plan on having the head thoroughly gone through and will get ARP head studs, MLS head gasket, oversized valves if anyone makes any, a good port and polish job, and perhaps cams and upgraded springs retainers and all that fun stuff if i can find any. Does anyone make cams and other valve train components for these cars?
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Old 08-29-2007, 09:29 PM   #2
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Personally I think the best thing to do is a top mount log-style exhaust manifold and keeping the intake on the current side of the car. As far as cams the stock T5 turbo cams seem to be a common swap for T7 people. So you are already good there.
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Old 08-29-2007, 10:18 PM   #3
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Well IIRC the "best" combo for cams is the T5 intake and ng900 N/A exhaust cam.
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Old 08-29-2007, 10:40 PM   #4
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Don't use runner material for the turbo manifold that is so large that you lose velocity. I personally think 1.6" ID is plenty. If you can avoid a log then do it. Even a "semi-log" or "short tubular" style is nice, such as this one I fabbed for my 88 prelude from my mig days:





I've fabricated numerous turbo manifolds but never one for my saab. I'll see if I can find some more pics. I'd love to see how yours turns out. While fully tubular manifolds are more work I feel the benefits make them worth while. My preference is still mild steel over stainless. Ceramic coat the mild steel and it is a superior material for this application. Usually, stainless eventually cracks from the stress and heat cycling. Schedule 10 or 40 mild steel is tough as hell.
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Old 08-30-2007, 03:03 AM   #5
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Thanks for the info Heath, mild steel is also a good load cheaper and i can MIG it instead of TIG. I'm probably going to go with the full tubular set up and I'll look into ceramic coating a mild steel set up instead of a stainless exhaust. I guess as far as cams go i might as well stick with what i have, but i'd like to try and oversize the valves by 1mm or so. Thanks for the quick replies.
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Old 08-30-2007, 05:27 AM   #6
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Can you make it so the turbo is sticking out the grill? Lika jet engine?
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can be prone to failure due to increased localized stresses in the hole penetrations
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Old 08-30-2007, 02:06 PM   #7
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I'm sure I could, but i'd hate to suck up small children and animals from the side walk =P

As a side note i have also done an AC delete, compressor and all
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