Had a hard time deciding whether to post an update, because I'll have another one in a couple days I think. But I have some cool pictures worth sharing so why not.
Waterjet parts!
Throttle body flange, I made the hole the same size as the gasket, assuming that the larger throttle body is that size, in case I use it instead.
Manifold flange, pretty much perfect.
Exhaust manifold to turbo flange, I got two of these to make my up-pipe.
I didn't design it this way, but the tubing I've chosen for the up-pipe actually fits right in to the hole and wedges in place. It'll need a little porting.
Downpipe flange, I messed up and forgot to enlarge the holes after using the measurements from stud to stud to locate the holes. The hole locations are perfect and it almost fits, I'll just have to chase it with a slightly larger drill.
Driver's side motor mount flange, all the bolt holes and clearances fit! I made it extra large just because, once everything's finished I may just cut the rear half of it off.
I'll need a 6mm spacer for the upper bolts, I'll either use purchased spacers (like washers) or buy some 6mm strip and drill it. Either way, easy fix.
I added this chunk of material to attach my alternator mount. I figured I'd roll it in with the same part to increase the overall strength and save on part count. I'll still have to adapt something though, once I buy my alternator.
On the passenger side, there were two machined bosses that weren't tapped. But the hole that was cast in to them was the exact size of the predrill. So I tapped them as is. Mmmm..
precision.
Fresh threads!
And again, all locations are right.
I made this side extra huge because all the different generations of this motor have different bolt patterns on this side. Case in point:
Ah. This lower engine girdle is from a '94, my engine is a '98, and I have a 2000 motor sitting on a pallet at my old job and its holes are completely different as well. I doubt I'll use this engine forever, as newer ones have updated internals that I'll need if I want to make more power. So all this extra material will allow me to just drill more holes and use it depending on what engine I bolt it to. Starting with one new hole right away, as I'll be using this girdle to fixture for the engine mount welds.
Cutting it a little close on the turbo drain, I might have to knock the corner off this plate for clearance if I tap this hole for a threaded fitting or anything. I probably will tap it because that makes it easier to use flexible line on the oil return.
So there we go, tomorrow I'm going to drop the engine back in the car and play with fits and dial in the final location, and nail down the up-pipe design, while playing with the throttle body to see if I can make progress there. Then on Friday I'll go to my old job to use their machine shop, where I hope to do final fly-cut on the oil pan for flatness, and machine recesses in the turbo flanges. They all have a shallow depression to sort of help seal them from exhaust leaks I guess. Can't really think of any other reason they'd be in there. Plus I can chase the mounting holes using a proper setup rather than trying to do it by hand. Stainless is not fun to drill.