Exhaust Manifold Build-up

[redhb240SXS13]

While this may not look like much to many, it is alot to me because I can almost start making my manifold. I'm just waiting on the head flange, wastegate flange, turbo inlet flange and a set of pre-cut collector pipes. This is going to be a copy of the Peakboost manifold. Should be sweet when I'm done. I'll keep you guys posted if there is any interest in this.

[scheffler]

those look big, what size are they i am sure that they are not but they look to big. I thouth they were for IC pipping.

Put something next to one for scale.

Anyway Good luck on your project and let us know how it goes.

[redhb240SXS13]

Yeah, I guess they do look big. They are 1.5" 304/304L SS. I'll update this as I make some progress.

[redhb240SXS13]

Oh boy, this is a big one. I've got everything in that I ordered and today I began welding the turbo inlet to the collector. Fit up was sub-par and I had to do alot of filling. Should flow fine once I go back and polish it up a bit. Also my head flange was machined for 1.5" schedule 10 pipe, not 1.5" tube. So I had to go around the shop and dig up some new 90 degree elbows that are schedule 10 pipe. Luckily I found some so I don't have to order anything new. And finally the picters cause we all love picters!

[Skeeg]

pretty slick man... keep updating for sure!

[esahuque]

Damn, I wish I could weld. My dad tried to teach me before he passed away, but i was like 12 I was to interested in girls at the time, I wouldn't pay attention to him. . Nice work keep us updated. I always love to see DIY work. BUILT not BOUGHT that's what I always say.

[WDRacing]

Good looking collector so far man...

[redhb240SXS13]

Thanks for the compliments guys. I'll try to update daily, because I should be working on it everyday. As far as Built over bought, I would much rather buy the peakboost mani, but it's expensive as hell. But it works out good because I have the resources to do it myself, so I get that good feeling of "Hey I made that!" And I'll only have $200 plus the time I work on it into it.

[NateDogg]

Looks like you put a lot of heat into that turbo flange when you welded it to the collector pipes. Did it warp at all?

[redhb240SXS13]

Nope no warpage. The collector took me about two hours to weld because I would weld about half an inch and then stop and blow air on it for about a minute to let it cool down completely. Plus I had a piece of brass clamped to it, so that was pretty much sucking up all the heat.

[redhb240SXS13]

Minor update. The collector is finished. Tomorrow begins the actual fabrication hopefully. Sorry for the crappy pictures, forgot the digital when I went to work today.

Hopefully I can get better pictures tomorrow, and another update of fab work. Oh yeah, WD or any other mod can you change the title to "Turbo Manifold Build" or something of the sorts?

[480sx]

Nice welds

Clean up the flange end of the collector with a dye grinder and that will be a beauty.

[redhb240SXS13]

Thank you sir. The welds on the flange end have been gone over again with just heat. This smooths out the bumps and what not. So, the welds on the flange are now clean and probably do not need to be ground. But hey, I might do it for S&G's!

[redhb240SXS13]

Update:I keep forgetting my damn camera. But, the collector is finished and cleaned up. I've started tacking up the piping, and that's about it. I'll have pictures tomorrow, cause I know we all love pictures around here .

[redhb240SXS13]

So, fabrication has begun. I'm building from cylinder 2 and 3 from the collector to the flange. Then I'll do the same for 1 and 4. This took me about an hour to do. So hopefully I won't have much more time in fabrication.

[scheffler]

Wow, I am suprized you stoped there. when I get into fabricating something I cant stop till it is done or i am missing something. Looking good so far.

[redhb240SXS13]

Yea, I didn't want to stop but it was 5 o'clock and all the other guys in the shop wanted to go home, so I really had no choice. LOL they peer pressured the hell outta me...

[redhb240SXS13]

Fabrication is complete. Brought the manifold home to ensure it would clear. Welding should begin sometime this week. Here are some pictures to stimulate this thread, which appears to be dead. Enjoy !

[lrb_2000]

does that sucker fit?

[redhb240SXS13]

Believe it or not, yes. It looks alot bigger in the pics, but it clears easily.

[eazye2000]

Just wanted to ask.. Where did you get your Head Flange from? That's pretty nice compared to some that are out there.WeiRtech makes them for about 40-42 bucks shipped, but they are just 3/8 Mild Steel. No port matching, and just a round hole.

I was looking at this one, but it requires you use Sch40 Pipe and that is a bit bigger than I wanted to use. http://www.bmcrace.com/product...d=170

Or maybe this one.http://straightlinespecialties...id=40

Just want your input because you've actually worked with a bare flange.
Modified by eazye2000 at 3:42 PM 2/17/2008

[redhb240SXS13]

I actually used the one from bmcrace.com. It is machined for sch. 40 pipe but I used sch. 5 pipe. It fits in the hole with barely any gap on either side, plus it is alot lighter. I would recommend bmcrace to anyone that is in the market for a head flange. The only downside is that it is mild steel, not stainless.

[scheffler]

That thing looks good dude. You plan on runing an internal WG, or have you not added the external port yet?

[Florida240sx]

Is there need to divide the flanges?

[scheffler]

I would say to distribute the pressure more evenly on the gaskets.

[redhb240SXS13]

schefler- I'll be running a 38mm Tial, I just haven't cut the hole yet.florida- Uhh...no comprende

[xsublimefrekx]

welds look real clean. I cant wait to see it mounted on the car.

[redhb240SXS13]

^^^Thanks. I started welding yesterday. No pics yet because I found out the company I work for requires a permit for outside cameras. So I'll update with pics once I get the permit.

[WDRacing]

florida- Uhh...no comprende

He means you should cut the manifold/head flange in between the runners to avoid expansion cracks. Not a bad idea honestly.

I love the mani so far except where the #2 and #3 runner meet the mani/head flange. The angle causes a turn which could be considered a slight restriction. But it's still more functional then a log type.

Waiting on the next set of pics

[redhb240SXS13]

Back from the dead, but with no pictures. Pipes at the head flange have been welded, and the hole for my wastegate tube has been cut. Also the wastegate tube is welded in. I can take camera phone pics or we can all wait until Monday for good pics?