I started on the exhaust. I began by getting the first 90 degrees to fit correctly, and then welded it all together. I welded on the inside of the flange as Corky Bell suggests, and then added a few inch wide welds on the outside.
I added a v-band to the end of that, and began the actual downpipe, which I thought was going to be hard with all the objects I had to avoid. It turned out pretty easy to do:
No video, nothing really that exciting. But it drives now, and I backed it down my driveway and back up. I also found 2 of my driveshaft bolts I had been looking for (after the driveshaft was in, of course, but I got high-grade replacements with new lock washers so who cares...), part of the v-band assembly for my Tial BOV, and... one of the missing nuts for a t-bolt clamp.
However, I managed to lose a 2.75" and a 2" T-bolt clamp.
The upper coolant pipe is leaking, again, from even smaller pinholes. I'm going to have to pull it off again and re-weld, again. I've also noticed that the silicone has to be really tight on pipes without beads on the ends. Big surprise.
There is also a small coolant leak coming from the rear of the engine, most likely the turbo coolant lines. I tightened them and will see.
But I've switched from the 1.3 bar cap that came with the new radiator to a 0.9 bar cap, which should help.
I added coolant and started it up for more than just 30 seconds. It ran for 15 minutes or so. Never warmed up fully, but close enough. I had a fuel leak that while slow, I didn't notice it (I couldn't smell since I was wearing a respirator) until the garage floor was soaked. There were a few loose clamps on the coolant pipes, and the upper coolant pipe has a few pinholes. I fixed one of pinholes on the car, but the other two are too close to the silicone joiner to weld in place. Lastly, the turbo oil feed line leaks. I tried to tighten it on the car but it didn't work, the turbo's going to have to come off, which isn't a huge deal, since I need to finish welding the wastegate flange on anyway.
Other than those minor things, everything appears to be working well.
I took off the secondaries and added the wastegate. I had my machine shop drill the initial hole, and then I just elongated it to match some 1-1/4" pipe cut at around 45 degrees.
Before I put the wastegate on, I fixed a few of the exhaust leaks and restarted:
