So having exhausted (sorry bad pun) that I could do with the rest of the car it was back to the main task in hand getting this engine to work.
So as mentioned above, I pulled the engine out, bolted the M90 to the back of it and dropped the lot back in so I could properly work out the rest of the engine mocking stuff.
Finally the correct flange for mating a downpipe to the back of my Turbo with the ultimate internal gate arrived so I was able to temporarily put it on and then offer the turbo upto the car to see what space i had to play with to make a downpipe.
The S60R manifold was installed, you'll note the turbo will be bolted pretty much near number 4 pot.
So with that in place it was time to offer the turbo up to the manifold and see how much room i would have for the downpipe. (excuse the poor pics its hard working holding a heavy turbo and trying to take pics)
I basically had 6 inches from the back of the flange to the firewall of the car, also its not easily seen but the downpipe would have been going straight enough into the brake servo.
Here's some crappy sketches i did at the time whilst asking opinions on wether i could get such a design to fit.
The main crux of the problem was trying to squeeze in the bloody wastegate pipe,
I could have just merged it all together like below pic but it completely nulled the point of buying the housing in the first place to get good boost control with the wastegate.
So I started to then look at creating more space in the area.
Looking down from above we can see the clutch MC and the Brake servo in place.
Now rememberig that 16v engines have the clutch MC inboard which then allows them to use a thinner brake servo. So Roger was dispatched to grab me an early whiteblock 960 servo from the scrapyard, he also attempted to find me 16v internal clutch stuff but has so far struck out. (keep an eye out for me UK guys)
So I ripped out the clutch and brake Servo's and Master Cylinders and fitted the 960 thin servo.
You can see that its moved the brake servo and subsquently the Master Cylinder back a good few inches.
At this point I got fed up of the car and this tricky exhaust problem and went on holiday to the SE 7.0 meet in the states.
I came back from holiday and robbed the estates headlights
I think 700's with no lights look pretty mean
But alas 1 light broke whilst trying to remove it as the studs holding it in had rusted and when removed the plastic then broke.
And I gave away my last set of ecodes to a visting american and now i have nothing to replace it with as the original ecodes from the saloon broke in exactly the same way!!! Arrggghhh
Then the headgasket went on the 940 and work on the 740 stopped again and it just kept on raining and raining.
Bollocks as they would say.....