Trionic

iTrader: (4)

I'm already single converted running an undivided on-center 62-1BB, tuff shaft, etc. but my header keeps falling apart and it's a huge pain trying to get to all the bolting each time I take everything apart to fix the header. The metal is some sort of low grade stainless that crumbles like cast iron when you try to repair it. There's no flex section in the DP, you can't reach any of the bolts with any tool invented by man and I'm tired of it. The 62-1 is an okay turbo, but there's better out there IMO.

So, I bought this:



Before the Holset arrived, I saw this T4 divided header on eBay for cheap. Comes with gaskets and bolting. I figure, heck for that price I might as well see what it's about, I can't hardly have the flanges cut and buy the tubing for that price ($100 w/shipping). Main tubing is about 2.25" OD or so and wastegate portion is 2" (can't get a caliper on it real well). The welds seem fine:



So.... there are four issues/questions that I'd like your learned opinion-about:

1. Will it fit with this header?,
2. Will it fit at all?,
3. What to do about flange mating?, and
4. I've considered cutting apart the 2 into 1 wastegate collector and running two smaller wastegates. I'm mainly looking for opinions here, what kind of gain in spool could I expect running two totally independent exhaust streams to this monster vs. having the common wastegate tubes connecting? It seems to me that they should be separate and that's the direction I'm leaning right now.

My current setup literally take about 2-3 hours to take apart because it's almost impossible to get to the bolting. I haven't taken it apart yet. Is there any hope at all that this turbo will fit in here with that header?



1 & 2. To me it just doesn't look like there's enough room with this header. This turbo literally weighs 38.5 lbs. and is freakin' huge. People have been running these so I'm sure I can make it fit somehow. But with this header? If not this one, which one? Should I just make my own?

3. Here is what I'm dealing with for flanges (traced the gaskets):





I post this mainly for information. The HX52 doesn't exactly have a T4 inlet and the bolt spacing isn't exactly standard T4 either (they're close enough to slot and make fit). So there's that and then the eBay header isn't exactly a standard T4 too, it's bigger which isn't bad, but there's not enough metal on the turbo flange to remove a wicked step between the two. The choices are to either make/buy an adapter or make a new header that has a real T4 flange on it.

4. Any recommendations for 2 small wastegates? I'm running a single Tial 44mm right now and it works great. The header is flanged for an HKS 50mm but it's not a problem changing that to V-band. I think if I go single it'll be one of the Vibrants. It just seems to me that two 38mm's (or maybe even smaller) would be more proper and spool better. But how much better? Worth it?

Opinions are welcome. Thanks guys!

stylEmon

iTrader: (2)

Sell that exhaust manifold and get one that has the correct T4 flange.

Trionic

iTrader: (4)

I may do that. Whose manifold would maybe work with this turbo (weird flange aside)? Before I sell this one I'm going to pull everything apart and see if it positions the turbo in a spot where it'll fit. Heh heh, looking down in there I'm not so sure there's any spot at all where it'll fit.

stylEmon

iTrader: (2)

That turbo will fit in the engine bay, I've seen much bigger units.

www.turblown.net for the manifold.

killahrx7

port the holes on the turbine housing, it will work

bc_fd3s

iTrader: (2)

or weld on a new flange?

catch-22

iTrader: (2)

That mani is going to crack on you cause i have WH1E which is a little smaller and with the weight of these turbos and no bracing usually ends up bad because the stainless is slightly thicker than a peice of paper. I know non-ebay manifolds are pricey but its worth it in the long run.

Trionic

iTrader: (4)

Thanks. I think I'm going to fab my own in SCH10 304SS pipe and 1/2" plate flanges. I spent some time talking with one of the metallurgists in my company (ex NASA, phd type guy) and he recommended 304HSS SCH20 if I could find it. The SCH10 L is cheap and easier to find so I'll see what happens.

The good thing is that I have access through some artisan friends to a good water jet shop. I think I'll probably just do a custom full divided shorty with dual 38mm wastegates and then make a DP to fit too. A pain but if I'm doing it I might as well do it right. Heh, if that turbo will fit in there at all, looks tight...I'm trusting you guys that it'll fit.

catch-22

iTrader: (2)

I bought a dodge diesel 4in down pipe and it was the perfect shape just a little long. Might save you some time to go this route.

The Shaolin

iTrader: (5)

What the heck kinda flange is that on the manifold?! The compressor is a divided T4, I have no idea what that garbage is on the manifold.

You get what you pay for. I think you paid for some thin walled, low grade stainless that will have trouble supporting 40 pounds of turbo+exhaust and wastegates hanging off of it. If it even fits, all the welds are going to crack bad when it starts heat cycling. Looks like OBX quality.

If you can make your own manifold, that's really the best option here. If you can't weld, or can't weld great, build your manifold out of PVC pipe and take it to a weldor.

I'd just bite the bullet, take the car apart, and get an awesome manifold on there to match that beast of a turbo. Good luck.

Also, look into 321ss or 318...304 expands a ton when heated and it's hard to brace everything. From what I've read, a lot of people start with 304 and then make a better manifold later.

SmogSUX

iTrader: (12)

Throwing this out there...what's wrong with the 62-1 BB turbo? If it's BB your spool should be decent and you should be making decent power too...and yeah that manifold will fall apart just like the one you have on your car.

hkp

iTrader: (2)

i loved my hx52 on my turboII, wish i could afford a fuel system and i would put it on the fd. i wonder what power the stock system could handle?

The Shaolin

iTrader: (5)

I'm sure you could find it with some digging. Fuel is one thing you shouldn't really gamble on though.