Manifold building adventure

[r33_gtst]

So cool man, I love this thread

[GTR-Dad]

Have you thought about a twin scroll setup?

[Zacho]

Have you thought about a twin scroll setup?

I have mixed feelings about it, especially on a T3 frame.

My issue is while TS is proven to show gains, they aren't anything to boast about really (IMO). You have to spend a considerable amount of money to run it (TS housing, TS manifold option, Usually 2x wastegate) and the return isn't too spectacular.

I spend lots of time on supraforums and It has surprised me the quick spool valve hasn't rubbed off on the RB community. Some of the graphs before and after are pretty impressive. But once again these returns really show up on a T4 frame 67mm+.

[r33_gtst]

The quick spool valve is a pretty cool device but some tuning software doesn't work with it.
I love to drop one into my set up but the turbo would sit too high and hit the hood, need modification for the down pipe, and I'd have to scrap the power fc for a haltec. All good ideas just not within the budget. Priority things to do before that.
The gains are impressive and it's a simple design. I do remember at one point seeing an intake gasket that goes between the IM and throttle body that is meant to improve flow. My dd will have to suffer the hundredths rpm's for the time being.

Keep up the progress and pics. Looks awesome

[Zacho]

The quick spool valve is a pretty cool device but some tuning software doesn't work with it.
I love to drop one into my set up but the turbo would sit too high and hit the hood, need modification for the down pipe, and I'd have to scrap the power fc for a haltec. All good ideas just not within the budget. Priority things to do before that.
The gains are impressive and it's a simple design. I do remember at one point seeing an intake gasket that goes between the IM and throttle body that is meant to improve flow. My dd will have to suffer the hundredths rpm's for the time being.

Keep up the progress and pics. Looks awesome

You can use them regardless of management. Just use a hobbs switch. But I definitely hear you, sounds like your circumstances don't really leave it as an option. I can't imagine an HX40 with a cheapo manifold(assuming you have one?) isn't the best combo for spool.

Got #5 done today and finished 2. I'm making decent time, about 3 hours per runner.

[leeaspin]

For your starts...start low on your stop and then drag your puddle back to the top of your last dime and slowly add rod. It takes a lot of practice for a clean start but sure looks good when you get it down

Awesome job so far man! Maybe this will inspire more people to the whole DIY concept.

[Zacho]

For your starts...start low on your stop and then drag your puddle back to the top of your last dime and slowly add rod. It takes a lot of practice for a clean start but sure looks good when you get it down

Awesome job so far man! Maybe this will inspire more people to the whole DIY concept.

It takes time to get this down. I never really start low on the stop I'll have to get into that habit. Makes a big difference since welding small diameter pipe takes me a few stops/starts.

EDIT: Volume was checked of each runner so far. 1&6 are almost identical. 2&5 are extremely close as well. All are within 7.5%

Another runner finished today.



You can see I am making the rearmost runners pretty tight but I want to be able to fit a 4'' downpipe there.


Somewhat slow on my own manifold...but I'm also building one of these for a friends SR.

[Bugsly17]

Make me a manifold for my Subaru...

[Zacho]

#5 done. At first I was confident I could easily get at all the collector/runner joints but this may prove to be extremely tricky. I've got to decide which runner should be welded last.

I am back at school & recently have not been feeling 100% so I haven't got as much done as I would like.

[Zacho]

Test fit today. Small issue, #3 has so little clearance to the engine mount that I'm going to re-do.



Clears PS hardline


Plenty of room for wg and dp

[Zacho]

So I completed all the runners finally. Some of the more keen eyed people will notice I re-did #3.




Intended wastegate location

[Zacho]

Been a little while. Worked on it a bit recently. I had to go test fit it again on my car after the revisions. Everything clears OK which means I was able to move on to welding it up.

My plan of attack is to run as much of the root passes on the runners possible while everything is still attached. I have had issues in the past where I remove all runners just tacked and then weld them on the bench. Problem is everything moves enough from the heat that it doesn't line up well afterwards.



Did the wg flange today as well

[rolyaT]

Damn nice bead on that WG flange man. Very consistent.

[Zacho]

Getting down to it again. I've developed a plan of attack so the final welds aren't a complete pain. I leave 1 section attatched to the collector/head flange for each runner. Get the really awkward position welds out of the way right off the bat then just piece it together in order of : 2,1,3,5,6,4

1/2 pass:




To avoid warping I bolt down/clamp to a 5/8'' slab of aluminum. It sucks the heat out of the flange really well.


Head flange welds not the prettiest. It is tough when I'm using 1 1/4 pipe in 1 1/2 recesses.

[ColinR33]

Zach, that is a work of art. The time, care and obvious pride you take in the fabrication process is refreshing to see!