Manifold building adventure

[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!

[SkyLizzle]

Heya gorgeous work first off! and 2ndly how much $$'s are you in as far as materials?

[Zacho]

Thanks for the words Colin.

Heya gorgeous work first off! and 2ndly how much $$'s are you in as far as materials?

With coating/porting around 450 all said and done. I get a really good deal through work on the weld el's (the 90 & 45 degree sch40 bends). This doesn't include my jigs or the MASSIVE amount of time required. If you wonder why $1200-2000 cost what they do...these things take an enormous amount of time and patience.

[Zacho]

It's all finished, just have some grinding to do on the ports. Then it is off to get coated Monday.

[scottygtr]

That looks amazing! Nice work

[Zacho]

Some better pictures. Nothing is cleaned up on it yet. Some of the head flange welds aren't the prettiest but the weld puddle was always trying to wash out on me since I was using 1 1/4'' pipe in 1 1/2'' recesses. Lesson learned for next time.

I think my patience paid off. The head flange has almost zero warp. I'm going to run it on a belt grinder very briefly to make sure.




Here you can see in the corner I also welded the insides of the turbine flange.


All that is left is sandblast/coating/a little port work.