2006 Mitsubishi Lancer EVO IX - Project 4G64 MIVEC Part 3

Full-Race hand-fabricated the twin-scroll manifold used to feed our BorgWarner turbo from eight-gauge T304H stainless-steel, and then robotically TIG welded it to perfection. The runners are nearly equal length and attached to extra thick, stainless flanges to prevent cracking. The cylinder head flange features a nicely machined transition into the runners, ensuring smooth exhaust flow into the manifold. Two V-band flanges allow exhaust gas to pass through dual wastegates and out to the atmosphere through our custom-made dump tubes. Overall, the manifold is a beautiful piece and includes a lifetime warranty against cracking. To further improve exhaust gas velocity and reduce under-hood temperature, we added a ceramic exhaust coating to the manifold, turbine housing, and downpipe.

With our larger turbo in place, we were eager to turn up the boost and make more power, but before doing so, had to counteract the elevated charge temperatures resulting from increased pressure-a situation our factory intercooler wouldn't be able to handle. We placed a call to AMS Performance in Chicago, IL, and purchased their upgraded, direct-replacement, 20x12.4x3.5-inch, bar-and-plate intercooler kit. AMS has been selling their popular intercooler kit for years, but recently made a significant upgrade to the design. Whereas most aftermarket EVO intercoolers feature fabricated sheetmetal end tanks that do not provide the best transition into and out of cores, with the aid of SolidWorks software, AMS improved theirs with cast-aluminum end tanks, which offer minimal pressure drop and install with zero modification to the bumper beam. To complete the connection between our turbo, intercooler and throttle body, we used an AMS 2.5-inch intercooler pipe kit, including high-quality silicone hoses and stainless steel clamps. Some modification was required to work with our unique turbo/manifold/block/head combination, since the AMS kit is an OEM replacement for the EVO IX and its native components.

To control the pressure on both sides of our turbo system, we turned to Synapse Engineering for their wastegates and blow-off valve. Their products are unique in that they use a fast-acting piston actuator that is sealed by O-rings, in place of a conventional diaphragm. Twin 50mm wastegates attach via V-band clamps and vent excess exhaust from both sides of our twin-scroll manifold, while the Synapse blow-off valve mounts to our AMS intercooler pipe kit via a standard Tial 50mm flange. Both wastegates and the blow-off valve are plumbed using a "Boost Connect" kit from Synapse, designed to securely fasten hoses using quick-connect fittings that cannot easily be dislodged or shaken loose, once pushed into place.

Look for the fourth and final chapter of our 4G64 build, as we install an Aeromotive Stealth fuel system, Fragola fittings and steel-braided lines, and a Vi-Pec ECU tuned by Apex Speed Technology, and prepare to shake down the engine and put the BorgWarner twin-scroll to the test on the dyno.Will our MIVEC 4G64 have what it takes to produce a truly streetable 500 whp?