Thats the NEW goal. My last one was last spring

 

Would you need to install a gasket between the turbo and the manifold. and what kind of material will it be?

 

Well I got back to it after waiting for my wastegate to arrive. Now it's 100% done! Only took since last aug What do you think?

 

It's so simple, but oh so nice. How are you going to finish it? As in, paint, wrap or some sort of coating?

 

yeah... u should go for the polish and then ceramic coating

 

Not sure, I was thinking of just leaving it like that and running it. Would that be a problem?

 

damn that's some nice welding. how much was for everything? i'm guessing i need a manifold too when i get my new turbo, can u give me a run down on the materials and where you get them to make the turbo manifold?

-mike

 

haha, if you go back 6 pages and look at it all it shows everything in detail but thats a lot of work so I'll give you a quick rundown.
raw material:
1/2" plate for flanges $30
weld els 9 @ ~$4.50 a piece (1.5" 4, 45 deg and 2, 90 deg for the main runners) (1.25" 3, 90 deg for the wastegate runners)
got 3' of the 1.5 sch 10 1.5 pipe and 3' of the sch 10 1.25 pipe @ $5/foot. (only needed 1' each)
so.. ~100 bucks for raw material
gave a friend $40 for letting me use his TIG welder

So about $140 for the manifold but TONS of time thinking of how I wanted to do it and actually cutting/grinding/forming and welding.

This is the way to do it if you are money poor and time rich, or if you just want the bragging rights to say "yeah I made that" when people look under you hood

 

It looks fantasitic !

I will send you some pics of my new mainifold (hope to have it done this week!)

P.S. that FMIC looks nice too

 

So how much for it shipped to Oregon?

 

Looks great dude!
Let's see how it works now

-Manolis

 

amazing, i guess i'm going to try this **** out and ask some of my welding buddies to lend me their welder.

good job on your setup! your an inspiration to all!

-mike

 

Rice Racing- thanks, I'll be looking forward to seeing your manifold. Yeah... that I/C, is ok I guess
88fc3sw/HX83- haha, good one! not for sale... well unless you have TONS of $ you are willing to give me
Manolis D- Yeah if it were only that simple... still need a ECU and a bunch of small stuff.
600HP CLUB- thanks for the kind words

 

i guess i won't do the same design because i notice your making it for a first gen, but i'm for sure going to build a custom manifold because i'm cheap and i save about 260 for an undivided cast-iron manifold from hks, with about 150 for a divide stainless manifold by me. so what you use to measure everything right?

-mike

 

Yeah, mine is for a FB so I had some extra room to work with. I went fully divided and equal length. Making it like I did was actually not all that hard (for the main runners) just 3" straight out from the flange, 45, another 45, 90 then I had to form pieces to the T4 flange that were about another 2" long. The best advice I can give is to have a roll of masking tape near buy. It works awsome for holding the pieces together.

 

A little off-topic, but not much -- I apoligize if you've already covered this, but I don't remember reading it: How did you go about welding all this up? Is this TIG or MIG welded? My father already has a MIG welder and I was hoping to accomplish some of the same things both for my exhaust manifold and IC piping. Would MIG be satisfactory? Benefits of TIG welding? If you know of threads that cover some of this, please point me in that direction. Thanks!!

 

I used a TIG welder to do it all. For this situation a TIG is the best because you can spend more time welding it/do a more precise job. But if you make it out of regular steel and use pipe I'm guessing it would weld up nice also.
I'm not sure how good of a job you can do welding I/C tubing with a MIG unless you use small diameter wire and very low current?

 

Just to let you guys know that may be interested I've got a rough tune into the car (still need to do a little fine tuning) and it's running awsome! The manifold has been everything I hoped for and more. No cracks and holds that heavy turbo up like a champ. The TD07 spolls faster than expected, the wastegate is wide open at 3300rpm (7.25 psi spring) and the car flies! Once I hit about 4500 in 2nd gear the tires fry and pulls like a bastard in the upper gears. I gave a bud a ride that has a high 11 sec car and he said I'm right there with him. So to anyone that is thinking about making your own manifold... DO IT! It's cheeper, better and way cooler if you can tell people "yeah, I made that"
Anyways, just thought I'd give a update

 

Excellent ! You have done us all proud .........

BTW how is your IC

Great to see the responce is up there, tunned pipes and your freeeeee flowing design obviously are the shot

 

I blew the end tanks off the damn IC! shudda never bought that POS.... but really, it's awsome! Cruising on a 85 deg f day intake air temps are 95-100 deg f. Seems to be working good! What were your intake air temps with that IC??
How is your project comming along?? Haven't herd much lately.

 

LOL... @ 20 psi my efficiency was around %88 at its peak and droped to around %82 at speeds around 200kph after 15seconds or more of continual high boost.

With some clever ducting on the leading edge of the IC (to force air through it) and water injection pre compressor the Eff peaked at %90 and droped of to a consistent %86 when running around 60lb/min of air through it.

TIG TIG TIG, I am setting up and it takes a while to be a proficient Aluminium welder (other materials were suprisingly easy !) I feel I am on top of it now (doing some excellent work BTW) and should finish fabricating the myriad of things I require to finish my mild power upgrade. Should not be too far away, I will keep you all posted with some nice pics and a few results when time allows.

Congrats on your car, wait for the cooler weather and wind up the boost to 20+psi and start spinning those wheels in the top of 3rd @ 90mph

 

haha, I'm having enough fun with 7 psi let alone 20! I'm sure I will eventually turn the boost up to 15 but that will require larger rear tires for sure! Right now I'm enjoying the car a lot and in the process of impressing friends with it
Thanks for the info and hope to see pic's of your set up soon!

 

Thats what its all about at the end of the day, having fun

I know when I did my Ignition upgrade and realy could use all the performance the engine was capable of I could not wipe the smile of my face !!!! I drove the car every night (have to drvie 30km to get to it then) took my mates for drives, hell even let one of them drive it just so I could watch it from the side of the road Drove it that much at such high power I cracked the diff housing !

Enjoy every minute

 

wow... another person who broke their diff housing...

someone i won't mentioned snaped and broke a hole large enough to fit a volleyball into the diff casing.
=)

setzep, where did u learn to weld?

 

Wow, cracked diff housing! Did it lock up or just leak gear lube on the road?

All my welding has been self taught. Still can't weld aluminum and not the best at welding mild steel with the TIG.. Welding the 304 was cake.