the manifold from hell begins

[themadscientist]

Alright, what started as a joke kind of got out of hand. I put some twins sitting by my engine as a goof and people thought I was serious. Well I like goofy sick things so I decided to do it for the hell of it.I need to build a mock up for this thing that I will then use to build a jig which will keep the whole thing from shifting when the real manifold gets welded together. I ordered mild steel U bends from Summit of the same size as the stainless I will be using on the actual manifold.I will be using two Trust TD05H18Gs and two HKS standard wastegates.

First I dropped in a CA block and head to simulate my engine installed.

Then I used some straps to hold the turbos into the positions I want them. There is very little room but it looks like they will just fit.

I need to feed #1 and #4 into the front turbo. #4 will pass over the runners for #2 and #3 which will feed the back turbo. I am not sure how in the hell I will run the front gate. It will be a challenge.

The good news for the back turbo and wastegate is with the AC lines pulled I have room for a nice sweeping U-bend and there is adequate space for the back gate.

The outlet from the front turbo will pass under the manifold runners and the back turbo will have an elbow and head straight down. I will tuck the rear wastegate between the strut tower and firewall and feed it back into the back outlet pipe. It looks like the front gate will end up between the front turbo and the engine and feed into the front turbo's outlet pipe. Oil feed lines should not be a problem but the drain backs are going to be tricky I think. It got dark and the mosquitoes started to attack so I had to wrap it up for tonight. I hope to get #3 and #1 cut and pieced together tomorrow. stay tuned.

[float_6969]

I'd say it's looking good, but it looks like poop. So instead I'll say that it has lot of potential.

[chicos240]

Dude....you have wayyyyy too much time on your hands....but when you pull this off...mad props...actually mad props for trying

[ragenasian]

I'd say it's looking good, but it looks like poop. So instead I'll say that it has lot of potential.

Come on Float that is just harsh

[1unar3clipse]

Isn't it funny when those little jokes or goofy things come to life and you find yourself in a banana suit going door to door trying to sell off some random "herbal enhancement" pills you got from the dollar store to pretty much who ever will open the door and listen to you speak for more than 3 minutes before asking why your in a banana suit.

Looks good... MOAR!

[MasterZenki]

Isn't it funny when those little jokes or goofy things come to life and you find yourself in a banana suit going door to door trying to sell off some random "herbal enhancement" pills you got from the dollar store to pretty much who ever will open the door and listen to you speak for more than 3 minutes before asking why your in a banana suit.

Looks good... MOAR!

<hr>

i cant wait to see this run...or blow up...or get partially finished...

[nvrplzd240]

That's awesome bro.

Good luck with it and def. keep us updated!!

[1unar3clipse]

I will post the video on Youtube someday, its one of those things you do to see peoples reactions.

[r34 gtr]

Yeah, you pretty much have way too much free time, and thats coming from ME!

[mdubc405]

man thats gonna be sick!!!!!!!!!!! i cant even wait till its finished

[eds13]

thats sick man, freakin RHD... -_-

[r34 gtr]

Its still got nothing on the truck

[themadscientist]

truck?

[MeanGreenS13]

you = sick in the head

[themadscientist]

ding! ding! ding! bingo

[eds13]

truck?

where you been mike??

[MasterZenki]

wow...im turned on but i hate it.... do i like it?

[Jiggyfry]

Awsome project.

Isn't it funny when those little jokes or goofy things come to life and you find yourself in a banana suit going door to door trying to sell off some random "herbal enhancement" pills you got from the dollar store to pretty much who ever will open the door and listen to you speak for more than 3 minutes before asking why your in a banana suit.

Looks good... MOAR!

Modified by jiggy180 at 9:50 AM 10/20/2007

[themadscientist]

where you been mike??

having sex, sorry, my mistake.

[tnslide80]

yay for crazy....that will be awsome.....where is the stroker ca???

[themadscientist]

this manifold will go on that engine. Now, with money being like it is and all the crazy expensive stuff that engine needs I will have to drop a temporary engine in for the time being.

[dash]

only reason for this is the "wow" factor. Like adding a throttle body to the other end of your intake or wiring in 4 more spark plugs etc.

you may find manifold pictures of this tt 4cyl mitsu setuphttp://www.doitbig.org/coltboostin/pics/4GX7/done/Two ebay $150 T3 turbos hit 560hp atw breathing thru a $30 stock junkyard hyundai(DSM) head. 24psi @4800rpm he says, 2.4L.

Just one 18g/td05 in a 7cm exhaust housing would make a responsive killer street ca18, with impressive high boost capabilities to boot.Obviously not what you're after here tho.

[themadscientist]

If it runs like a dog it's coming off, no matter how much "wow" it has. I expect it to be very laggy and only wake up when I fully intend it to do then pull strong at the top. I can see runner smaller than normal ID pipes to help keep velocity up on the actual manifold. I can step down to smaller housings before I decide it isn't working though, these are 8CM, big for an average RB26.

[themadscientist]

I picked up the flanges for the head end of the manifold from my machinist. 5/8" steel plate fo yo azz bishes! These were plasma cut and machined out for me from a big plate of scrap steel I got from a metal yard. They are incredibly heavy and dwarf even the flanges on my cast iron manifolds; sealing should be no problem.

These were originally going to be just for the mock up but the more I look at them the more I think they will be up to the task for the real manifold.



Stainless pipe was my original plan but I was looking at a a manifold my machinist made out of weld els and it was ruthless. Very weighty but 10 years and no cracks, locally available and easy to weld. It looks very attractive. I have access to a real nice MIG, maybe I am feeling daring enough to do everything on this manifold up to final welding. I'm not sure yet.

[MeanGreenS13]

penetration is the key or it will crack, thats the problem with half the ebay manifolds out there

[Bwana]

Use what you have to tack it all together Mike, then take it to a welder and have it properly tiged.

[float_6969]

Use what you have to tack it all together Mike, then take it to a welder and have it properly tiged.

You need some sort of inert gas to properly weld the pipes to get a good weld as well.

Tack it with the stick/MIG then get it done right. You know what happens when you half *** stuff....

[disrupt]

Just putting my two cents out there.

what kind of steel are your flanges made out of? You are planning on similer material for the piping. If your flanges are mild steel and the piping stainless, it will be very hard to weld the two together let alone it survive the stress from heat expansion and weight of the manifold piping and turbines.

If both components are made of stainless. Mig tack, make sure you use similar mig wire and argon, not co2 gas. take it to someone with a tig welder and have them weld it place all sides continuous fillet welds. the tig needs at least a 200 amp power source to achieve full penatration depending on material thickness. stick is not great for tacking even with stailess electrodes because typically with stick went the arc to stuck the temperature has not reached an ideal temperature to produce a full penatration weld. you will get cold lap which is when the edge of the bead has lack of penatration and leaves a small overlap. Which if full penatration is not reached while fillet welded there is a chance that air or other impurities can be trapped in the weld which is where a crack will start. Better to weld a part with out a tack (regardless of mig or stick tacks), grinds off the tack and then continues to finish the tig weld you are okay.

Also while grinding, cutting with stainless wear a mask. your lungs will not be able to remove it over time like carbon steel filings.

Sweet project.

[ST240]

Lol i love you TMS. Youre always up to the most wacked out stuff but its so interesting. I love custom-self fab. Its what i hope to be doing one day when im done school. Keep it up!

[Liquid_Neon]

can i call you dr wily?cause he is one of the few mad scientists that come to mind with a crazy plan like this

Build mega man after you finish this!

or would it be more appropriate to have you build his brother proto man?