Conventionally, turbocharger bearing housings are cast, and then oil passageways are drilled or bored into the casting. As a result, bores are limited to straight lines extending from drill access points. Greater design flexibility is provided by pre-staging in a mold a collection of metal pipes which will define one or more of oil, air and water galleries, and then casting a bearing housing around the pipes. This provides almost unlimited freedom in shaping and locating the oil bores and other features.