How it's done - There were two main challenges -
(1) How could I modify the Intake manifold in order to accept a blow through type design
(2) Where to put the original Throttle Body and how to mount it.
To the machine shop. With the 2.2TI "log" manifold and a band saw: cut off the restrictive elbow that diverts air from the turbo into the intake. I then used the origonal throttle body mounting plate and pipe (origonally bolted to the intake manifold and rubber-hosed to the turbo) and you can weld that directly onto the cut intake manifold. Carefully measure for clearance with the brake master cylinder, then with the head for bolt clearance for the throttle body, and everything should fit with about 2 inches to spare. Machinist Paul Baker welded the first one together and Dremel'ed the inner junction smooth, and, for that favor, the design has been given the name "Baker Manifold."
The assembly is like this - The throttle body is mounted sideways, allowing use
of the original throttle cable, and TPS/AIS wiring.
- The turbo is unchanged and mounted in it's original position.
- The original throttle body - used a heavy plastic cap to divert air from the original air box into the throttle body: use that to divert the air from the intercooler.
- Here's another issue to be dealt with yet: You want to use a big intercooler, but do not want to deal with mounting it in the nose and creating alot of custom intercooler tubing? Get a big intercooler from a Volvo 740, which is about the same size as the origonal non-intercooled Daytona radiator (therefore, it makes sense to mount it in place of the radiator.)