So I am sourcing and pricing out the cost to make my own turbo manifold, downpipe, hot pipe, and water/oil lines. I had a few question with those with experience in making their own. Links and advice would be very helpful

I saw a few different flanges for sale. I wanted one machined so the pipe fits into the flange for stronger connection. Which company makes a quality flange?

Manifold tubing, what size outter diameter usually fits in those flanges that are sold? I was debating on using mandrel ss tubing, but I saw the only mandrel tubing available was the thinner gauge. So it seems like most people are using the thicker cast elbows to make theirs. Anyone have their recommendation of minimum thickness, links for shopping?

I'm going to do a little more research, but I am looking for around a solid 300whp on 91 octane. High 200 range , low 300hp range, depending on dyno. I was looking into this to4e turbo, and I was going to try to make my manifold twin entry. Anyone recommend a size? Garrett T04E : atpturbo.com

The reason I am thinking of going through this trouble is because I have had my share of old not rebuildable s5 t2 hybrid turbochargers. I have fabrication equipment at my work. The only thing I might have to find is another gas tank to purge while I do my welding. My car already has fuel requirements, fmic, megasquirt ecu. I can get a good discount on Garret turbos through my work. I'm hoping to spend 1300-$1500 for parts and materials at the end, and many hours of quality work. This will be my first attempt at making a manifold, and why not the first time with an engine with 2 exhaust ports, and 2 ports on the turbo?

 

I will be using one wastegate, but I'm going to make a divider to the wastegate. I'll leave a small gap for metal expansion. I'm debating on how small of tubing to make for the pipes going to the wastegate. So much thinking about this whole project.

 

You would prolly get a good amount of feedback in the single turbo section. You can PM a mod to have it moved.

 

This is a good place to start.

If I were you I would look into a BW turbo. 1.5" tubing runnings & .120 wall & 16" runners, this would work very well good luck.


Chris.

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http://www.mandrel-bends.com/catalog/

Sorry forgot the link.

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Thanks for the help! I was doing a little research and found .120" was a 11 gauge. I had this whole plan of making my 1/2" flange match the ports but then transition it to the ID of the 11 gauge 304 tube. I lost a lot of sleep over it even though it probable wouldn't make a diference.

Now I'm leaning towards just getting a bnr turbo, and spending money elsewhere on the car.

I calculated around $1600 -1700 plus many many hours of work for a custom fabricated turbo. I get a good discount on parts,but not the 304 stainless mandrel bends I would be buying.

Or $900ish for a bnr turbo I could bolt on in an hour or 2, and afford with one paycheck.

When I do spend the time and money, maybe I'll have enough for a nice ball bearing turbo. Money was part of it, but also finding a reliable used turbo was another factor. I'm keeping my fingers crossed with the bnr turbo reliability. I've already been through 3 stock turbos and stock rebuilds! Oh yeah, it's 2013 almost 2014, I hope my 1989 turbo won't burn oil

 

Try Racing Beat or Burns Stainless, both in OC.