Paleyjim....i would go with a straight reducer from turbo to tube, then a 45° elbow in the midle tube from turbo,...or end of tube, it depend from radius you can use/play to the 90° elbow from intake upper plate
I made a little more progress last night. I found that if you remove the spring from the hood, it is much easier to tell if/when the hood insulation contacts parts.
I made one slit in the tube with the chop saw and did a little additional grinding to get the slit to close back up ok. This was enough to get hood clearance.
I welded the tube up and ground it smooth. Welding was a treat, the back side of that bend is very thin PLUS that is the area of the slit that had a little gap so I had some burn through. Overall it turned out ok.
I'm still playing with the angles of the the compressor housing and the intake tube. I'm also deciding if I want to put a bead on the intake tube to retain the reducer. I'm pretty certain it will not be able to come off, so leaning toward skipping the bead. I think I will also shorten the tube a little bit. I think it will make assembly and alignment easier. I hate to cut it off before I'm certain that is the right direction.
I haven't been driving much. I took the truck out for for a quick test drive before I really sealed everything up just to make sure nothing was going to blow apart under boost. It sealed pretty well even with no gasket or sealant between the lower intake and my stainless plate. I could still hit 17 or 18 psi, but boost was slower to build and I had more smoke due to leaks. Everything held together just fine.
So I pulled it all apart and put a bead of silicone on the lower intake and just a touch on the vband as well. Today I went on a longer test drive. I didn't beat on it too hard, but hit 19 psi a few times. Stabbing the pedal left a pretty dark little cloud of smoke, but it cleared up quickly. I think the smoke clears a bit faster than it would before.
Power might be very slightly better, but I didn't get over to my standard full throttle test strip to know for sure.
Overall the project was a success. I still need to do some work to the CDR tube. It no longer routes properly now that I moved the compressor housing. But otherwise I should be ready to to start playing with water injection. That project is a ways off. I need to put brakes on a Subaru and have a couple of exhaust projects in my immediate future.
I recently pulled this back apart to seal it up better. My 300k engine has enough blowby to make the poor seal of my flange to the lower intake quite evident - by covering everything in a layer of oil and grime. My update from a year ago says I was building 19 psi of boost. This was down from the 20/21 psi that I was building after the HO injection pump. After reworking the flange to flatten it out, sealing up the pipe fittings better with pipe dope, and cleaning up some welds that appeared to be less than air tight... I'm happy to say that I'm again back to 21 psi of boost pressure at WOT.
Here's the grimy mess from the boost leaks combined with blowby:
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