Massive pic dump. Today was a huge day, we got a TON done. Found a bunch of undocumented issues that we had to work around, but in the end, we were triumphant.
A lot more detail here, if you're interested.
Fitment issues on the 99 fuel rail. Simply had to bend it gently outward on the vise.
Fitment issue (already corrected in the pic) to get the reroute BeGi spacer to fit. Had to cut the bottom half of the retainer for the plug at the back of the exhaust cam to make it fit.
Fitment issue (already corrected in the pic) of the 1.6L FPR. Had to gently bend the output tube because it was interfering directly with the air-space that the upper intake manifold wanted to be in:
Fitment issue (already corrected) where the upper intake manifold was interfering with the feed tube on the 99 fuel rail. Ground the manifold down with a sanding wheel a little at a time until we could see daylight.
Finally done with the issues and putting things to right. Vac line from the FPR, routed and with some loom cover to protect it from chafing on the bottom of the throttle body mount.
Clutch pron.
Fuel and coolant hoses run while its out of the car for convenience's sake, but otherwise ready to slide tab A into slot B.
Finally in! No pics of the process because that's an all-hands-on-deck affair. But I had to re-learn tricks on how to do the mounts, as the tricks I know for the NA mounts don't work for the wider / longer NB mounts. Took some time, but we got it done
More loom over the fuel hoses to prevent chaffing of those. Because that would be bad.
Jackson racing header and my custom intake installed. The JR header actually doesn't look too bad here, but it's a real POS, barely a step above eBay specials IMO. The welds are awful, the flanges are a bit crap... I'm so happy I got it used for very little money. EGR deleted by cutting & welding.
And some go faster parts from JamesCH. I didn't think I'd actually like it, but it feels SO right in the hand, so it's staying, and the Nardi Touch of Class wood-grain knob is going up for sale.
Still a few big jobs to do. Wiring modifications, a new throttle cable, different ECU, tuning, etc, but the heavy lifting has been completed.