Heres an old setup i made back in 05-06. I was looking to make a reliable AC compatible low boost setup that was stock looking in case i ever got pulled over. I wanted instant boost at low RPM's so i went with the IHI RHB5, my plan was for 10psi, so it fit the bill.
Heres the turbo, it was in good condition, It came off a ford probe, that was rear ended.
No shaft play, no end play, no burnt oil or cracked flapper housing.
Low budget means using regular steel elbows and flanges., tacked them up straight.
I couldnt find a flange locally or online at the time, so I fab'd up my own using a 1/2in steel plate and a drillpress.
The collector and flange welded up.
Bolted the turbo up, mocked it, and tacked it in place.
welded it up solid.
Here I am trying to cutout the holes for the inner runners with a hole saw that has seen better days. sprayed WD-40 so it wouldnt heat up too much.
This is what happens when you add to much pressure on the drill, it breaks the teeth, gets stuck and causes the drill to punch you in the chest.
Here it is all welded up, and cleaned up a bit. wasnt going for looks, just wanted it to be solid.
I went with the stock cast O2 housing. It clears the AC COmpressor.
2.5in steel for the rest of the downpipe. Bolts into the stock cat or testpipe.
Here it is all mounted up and whatnot. It looks stockish, kinda like a oldschool greddy or apex kit.
I figured i would make a heatshield to hide the turbo and keep the heat down. Made it out of some thin sheetmetal from homes depot.
tacked 3 bolts to the manifold and bolt the heatshield down. It looked pretty good and hid things a bit.
Poured some gasoline on a d series slug and lit the bitch, this makes an awesome candle.
Unffortunatly, due to money issues, I never got to use this setup. It sat in a box for a year then got sold, but it wasnt about the money, or the time spent. It was about the learning experience.