Here is the start of my exhaust manifold
 

I just started on this yesterday. I am going to see how fast I can get it done. Accually the truth is that I already had the flanges blueprinted and I already have all the matirials I need...I think. I dont have any waistgates yet but I will see how fast I can get just the turbo mounted. Here is the flange I made last night. This manifold will be made of 304SS and I am going to use two waistgates. Tomorrow I am going to make the turbine flange and maybe start fitting it to the car. I will post more tomorrow night.

Cool. Can't wait to see how it comes along. What size of piping will you be using?

Looks good!. Do yourself a favor, preheat the parts to 350-400 degrees F, and have a good backpurge and you can virtually eliminate the "Heat color" associated with welding stainless

Here is how far I got today.
 

Here is the turbine flange that I made today. It is the second prototype, cause I fuckered the first one up. Needless to say, it was a long day. I made a counterbore in the flange so that the tubing would fit right in.

snaptite
 

I also counterbored the engine flange. BTW I am using the same tubing as the other guy thats building his mani. It is 1.5" sch 10, it has a 1.9" O.D. and .109 wall. It is a little smaller than the exhaust ports but it matches the ports in the turbine housing almost perfect.

Tube shaping
 

Here is how I had to shape the weld L's to fit into my trick T4 flange.

fitment
 

This is how it fits together. I dont know weather I should weld on the inside or out. Advise?

closeup
 

pic

A decent start for two days work.
 

pic

Wow! looks great! You must be a machinist? The parts look like you did them on a CNC mill.
How did you form the weld L's to fit the flange so nicely? I simply heated mine up and formed them with a hammer/chisel. Took a while but turned out real good.
You're right the 1.5 sch 10 pipe fits a T04 flange like it was made to when you get it bent to shape. For me it was the pipe size of choice because I have the smaller cosmo 13B-RE exh ports so it matches almost perfect.
I welded as much as I could on the outside of the turbo flange and also welded the inside. On the engine flange I welded both outside and inside as well. I used the fusion method of welding where I could, seemed to turn out better than using filler rod (probably because of my inexperience with TIG welding).

Again good job! Keep us updated.

Ok another days work.
 

Well this thing took alot more turns than I thought it was gonna, and I am out of weld l's. So the mani is on hold till tue. when more show up. So here is what I got so far.

Oops I welded it to the wrong port.
 

Just kidding, I was having trouble keeping the runner length the same with the placement of my turbo, so I decided to have the runners cross over each other.

Another pic.
 

my jig

Where to plumb the waistgates from? Close to the motor or close to the turbo? Anyone?

i dont think it will matter, just that where you make the holes it dosnt interupt the exhaust flow too much going to the turbo

btw .... very nice fabrication!!!!

Wow, nice, makes mine look like a regular old hack job :)

https://www.rx7club.com/forum/showth...ustom+manifold

-Manolis

TTT

are u makign this? http://cgi.ebay.com/ebaymotors/ws/eB...tem=1876754521

that looks like a twin turbo mani

What is it going in? You really have the turbo flange sticking out far. I don't think that would even fit in my FB.
https://www.rx7club.com/forum/attach...postid=1397336

darkwaveboi- it's a single turbo manifold, thats a standard T04 flange you see there.

Kahren- he's making a custom manifold that has the two primarys cross each other. It will however do the same thing as the one on e-bay, just diferent design.

You could use that 3rd gen single turbo manifold on any 13B right??? Would it clear our t2 intake manifolds??

BTW, did you run any flow calculations to come up with the ideal tube length or are you just trying to make it equal length?

No I dont make those OBX manifolds, they look nice though . Accually this is my first one and hopefully it will turn out good. I've done custom exhaust work before and always wanted to make a manifold but couldn't justify it untill I got my new turbo, so away I go.

Oh and turbo guru's please tell me if you think I'm totally fucking this up.

I think the piping is way too long... I think that'll just be hitting the frame or the shock tower let alone trying to bolt a turbo to it as well ?? have you tryed to fit it in the car?

Yeah I think it sticks out too far myself.

But damn that turbo flange looks good!