making turbo manifold..

[JustenGT8]

i think someone needs a clue

fixed for you

WTF Greg?....anyone who doesn't want to share simply doesn't belong here You can't sit on here getting gaining info from others without giving in return, regardless of any commercial interest, that's just bullshit.

I suspect Linden would be well pissed at you for linking him to your bizzare statement... in point of fact he has provided welding tips... rightly so and well appreciated.

I can't think of anyone here who fits that profile, so luckily it appears few feel as you do and lucky for the rest of us you have little info to share

What size turbo Brett?...i have found the simpler and shorter runner manifolds (and therefore less bends) help with spool with large frame turbos.

[brett_celicacoupe]

GT3540 ford spec thing. still hoping to put the M90 on as well.

for future reference, these are what im looking at purchasing. http://www2.blackwoods.com.au/PartDe...rt_no=03130809

i ordered one of these the other day (still waiting) from titan motorsport. http://ebay.titanmotorsports.com/ima...BOV/PTPW46.jpg
they're supposed to be pretty new model.

maybe i should update my ride thread. 3rz is semi bolted into JZA80. i have 12weeks holidays from uni which im working on the car(s). ive been sidetracked by a fishing boat respray for the last week.

[JustenGT8]

Yeah righto....biggish for 2.7litres but still pretty tight in the turbine. Adding the SC makes it a whole new ballgame as you have to size everything up so much it feels wrong

All i can advise on the manifold design is make sure it'll flow a shitload I'm not telling you anything you don't know but with the SC, the exhaust side (and turbo compressor for that matter) are gonna see a bigger engine than 2.7lts

[jzk25]

Those elbows are the type I prefer. You still have to clean the mill scale off them though. I normally use about 100A(on my inverter TIG) to weld the pipe joins and up to 130 for the pipe to flange joins. Make sure you bolt the flange to a big rigid piece of steel like a C channel or you will be in a world of warpage pain.
In an A80 you are best running the gate down between the runners on the inside and positioning it down near the bellhousing. This allows room for the dump and gate return. Some manifolds poke a gate pipe out on the outside(easier to make i guess) which makes it very difficult to impossible to return the gate pipe. Also does a good job of melting the brake and clutch hydraulics.

Another thing to remember is to route number 4 runner in a way that allows room for the dump pipe.

Link to members ride and update please.

[Draven]

as mentioned, very cranky day.
disregard comments - with happy eyes they're just wrong.

[twentyEight]

For my 3S mani, I originally bought 12 long radius 90 degree 1 1/4" NB bends from Linden. And Chuck is right, needed one more and it was a Saturday arvo... Fucking Murphy and his god damned law...

As JSK25 said, don't bother with anything but long radius 90s, and get a metre of 1 1/4" NB Straight Pipe also for between the bends and the merge collector.

[brett_celicacoupe]

i didnt have any success with a drop saw in making the collector so i went all out with the mill.

highly recommend doing it this way if possible.

i rotated the indexing chuck at about 13deg relative to the bed. based on the flange dimensions i worked out what width i needed at the end of the pipe. then used a pair of squares to measure it. being a rectangular flange, one cut had to be more then the other






next step was to index the head 90deg. for 2 of the pipes the pipe needs to be rotated clockwise on the second cut, the other 2 need to be rotated anti-clockwise.




finally the end facing i did was indexed at 45deg between both the side cuts. this wasnt perfect but was very close and only need a little linishing at the end to have the whole job flush to go on the flange.



putting a square on it later i noticed it wasnt quite 90deg. this was possibly due to the pipe and/or mill cutter deflecting a little. once a pair of pipes were welded together it was possible to give it a quick linish to get it flat again and close the gap with all pipes together. this photo shows the slightly obtuse cut angle on each pipe.



and this is it all tacked together, im pretty happy with how it came out. never made a collector before so good learning experience.

still need to weld it all and transition the flange a bit more to both profiles

[shoom]

not to deride anyone's efforts thus far, but I thought this may be of interest to you guys. and for alloy work in general..

http://www.edge.au.com/faqs.htm

go to the bit entitled 'can I make my chassis out of aluminium?'

[twentyEight]

not to deride anyone's efforts thus far, but I thought this may be of interest to you guys. and for alloy work in general..

http://www.edge.au.com/faqs.htm

go to the bit entitled 'can I make my chassis out of aluminium?'

I don't see the relevance to this thread?

[sleepercorty]

heres one i make for my ca18 ke30 think i used 14 bends all up but was a while ago, just make sure you spend time making all the joins butt up nicely. i made my collector in the drop saw is easy once you work out the angles you need to cut. i used old toilet rolls and cut them up to make a practice collector then coppied that to make the steel ones.

[brett_celicacoupe]

3 million hours later.....

[e30-323ti]

3 million hours later.....

Looks Shit Hot Brett, well done.

@3m hrs, Good think it only cost you your patience then.....

[jzk25]

Give it a sandblasting and paint it with stove paint(or ceramic coat it if you want).

How's the flange warpage?

[Gary]

ive been considering a mill for a while now

you sir, have just pushed me over the edge

excellent work

[brett_celicacoupe]

Give it a sandblasting and paint it with stove paint(or ceramic coat it if you want).

How's the flange warpage?

interesting idea.....



no significant warpage in the flange at all! less then .5mm runout i reckon. i think ill still going to give the flange a surface though.

im sure you can see here why it stayed pretty straight....solid bit of channel



i ended up MIGing the whole thing as i couldnt get the TIG to work properly. maybe the gas was the wrong type or something?? anyway mig got good penetration.