These are a few shots of the original manifold that was designed for our motor, before we went with the longer runner version which puts the turbo further up front.
This one was designed to place the GT-42 in relatively the same spot the previous manifold, although it now gives much more clearance.... You are now able to get a 5" V-band on and off without first unbolting the turbo.... Unbolting the turbo is also easier and more accessable. The T6 flange is tucked just within the allowable space on the strut tower/fender.

 

A few more showing fitment and clearance around the LIM, tranisition from runner to flange, and full penetration weld seam.

 

And finally a few of the new manifold bolted up with the turbo in its new location. With the new intercooler, this setup will shave off about 18" from previous.

 

Looking good, I located my GT4202R in nearly the exact same place next to the WP housing.

 

WOW man. very nice work. good luck with the build. im not much of a RX-7 ''ROTORY'' person but does it move more air then a typical 4 banger motor? a 42r is a big turbo to move. ''where i come from''

 

substantially more.

 

Finished manifold...

 

looks great...

 

Simply beautiful.

 

how about an update, Casey?

 

??? Requesting an update ???

 

It's his tech thread, so calm down guys, he can answer when he wants...and since he posted this:...technically, that's the end of this thread. This is not a FS or "when can I buy one" or even a "what does it look like installed in a car" thread, so please, no one go there. He's just giving us a glimpse at some superior thinking and craftsmanship.

Dassall.

 

Where did you get your engine flange from? Manifolds look absolutely amazing too!!!!

 

Thread cleaned up again...last time I say this. This is a tech thread dedicated to the OP's work. It is not a FS thread, not a WTB thread and not a GG/BG thread. There are places for all of those kinds of posts. GO THERE AND POST.

Next guy that decides he can't go anywhere but here to post his problems or "how much" questions gets a nice month-long vacation from the website.

Guy goes on a two week vacation and all the problem threads go nutz. Was everyone just waiting for me to leave??

Mario III, SuperModerator

 

Thanks Mario,

Not to bring it up, but all those having issues have either been resolved, or I've been in contact with.

Now onto the good stuff...

I don't have any completed manifold pics of my set-up to post, however I wanted to share a few pics of a direction we may be taking with our manifolds. Personally I have always loved pie-cut exhaust systems, so I figured we'd better give it a go. We have a Mazak rotary laser which allows us to accurately cut any geometry into a pipe or tube to within .004", so we can use this to our benefit. No longer are we confined to the 45's or 90's degree offering of a standard elbow, nor the long or short radiuses. So, we had a go to see if it would turn out like I had planned it would. It did... and I'm hooked.

The runner pictured below is done using 1.5" sch5 pipe (1.90" OD, .065" wall (NA application... forced induction will be thicker of course). Each section has a 5 degree taper to it, for a total bend of 25 degrees. The other end is simply square cut seams in odere to dial in the settings. The weld seams are argon purged, and 100% fusion welded using NO filler rod. If you were blind-folded and ran your hand over the pipe you wouldn't know it was welded. The cast fitting on the end is simply a threaded fitting in which to supply argon. This is the direction the exhaust manifold and exhaust system on my own Z will take.


http://www.flickr.com/photos/20669521@N08/6040230044/http://www.flickr.com/photos/20669521@N08/6040230044/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6040237892/http://www.flickr.com/photos/20669521@N08/6040237892/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6039677491/http://www.flickr.com/photos/20669521@N08/6039677491/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6039674539/http://www.flickr.com/photos/20669521@N08/6039674539/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6040263360/http://www.flickr.com/photos/20669521@N08/6040263360/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6040276902/http://www.flickr.com/photos/20669521@N08/6040276902/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6039732459/http://www.flickr.com/photos/20669521@N08/6039732459/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6040293340/http://www.flickr.com/photos/20669521@N08/6040293340/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6039748951/http://www.flickr.com/photos/20669521@N08/6039748951/ by http://www.flickr.com/people/20669521@N08/, on Flickr

http://www.flickr.com/photos/20669521@N08/6040301192/http://www.flickr.com/photos/20669521@N08/6040301192/ by http://www.flickr.com/people/20669521@N08/, on Flickr

More pics to come!

 

Looks awesome Casey!

 

That is freakin' insane! It staggers the imagination how technology continues to push forward in so many fields. The city you are in is extremely lucky to have someone willing to spend the dime for this kind of over-the-top hardware. That is one wicked cool machine.

Now, let's see one of the manifolds done with that machine and then drop on a ceramic coat to see just how smooth it is.

 

The pipe is cut with lasers, however it is assembled and welded completely by hand. No robots or orbital welders on these bad boys.

 

sorry if i missed something. What are these lines for? are these welds or are they weak points to make the pipe bendable?

 

They're welds, just for the purpose of setting up the parameters on the welder.

 

take a video of this some how, this looks so damn intresting...
Its funny even thorugh a picture the welders bright spark made my eyes teary

 

holy #$(*&# that thing is awesome!

 

You'd really even consider covering that up??!! I'll see if I can get some video of the laser this week.

Thanks Skyler! If you think thats cool, wait a few more days....

Ha, it does doesn't it! In fact this is how I actually watch him welding half of the time... through a camera lens. Under the hood is even better.

Thanks!


We'll be re-doing one of our T6 manifolds to use pie-cuts exclusively instead of the elbows it was originally designed with. I'll have pictures up in a few days.

 

Those are the best welds I've ever seen. Honestly.

 

holy **** man, those are freaking sexy!