I am almost finished building my manifold. I just need to complete all the welding and it's finished. Here are some pics

 

Looks puuuurty

 

May I ask what kind of metal you used? I assume stainless steel, if so what grade as well? Also how did you get the bends in it?

 

I used 1/8 inch mild steel. I built it with 3 U bends. I decided since this was my first manifold I would go with mild steel since it's less expensive and there was a chance I might experience a lot of trial and error. My last manifold was thin gauged SS and it fell apart. I didn't build that one.

 

are you sponsored by aquafina. its in most of your pics. btw...its really nice.
kris

 

Thanks, that is real nice, what kind of turbo is it for?

 

I can't tell but it looks like you welded on the wrong wastegate flange.

The TiAl's should come with 3 flanges. Two look the same: they are flat on both sides and have a small recess for welding a tube into. These are the flanges that get welded. The third flange is the one with the valve seat beleved into it. You don't want to weld this flange because it *will* warp and your valve won't seal properly. I don't have a good picture of them assembled but the flange with the seat in it should be sandwiched in between the weld flange and the wastegate bottom, not welded on to the manifold.

If this isn't what you did then please ignore.. it's kind of hard to be sure from the pics. Otherwise it looks good. It locates the tubo nice and low.

..Dave

 

That's a good idea. Maybe I will give them a call and see if they would be interested in sponsoring me. I could endorse Aquafina for a water injection system. Honestly I don't even know why that bottle is there. I may have been using it at one time to cool down the tubes after they got hot from grinding on them.

The manifold is for a T04B 60-1, .7 AR comp, 1.00 AR turbine.

Is it just my computer or are the pictures not working anymore?

 

My WG only came with one flange. I called the supplier and they told me it should have come with another one so it was shipped to me separately. I was never aware that it was supposed to come with 3 flanges. I used this WG on my last setup and it seemed to seal well. I will be looking into this. Thanks for the info

 

I was just looking at another pic of the Tial 46mm installed and this person did it the same way I did.

 

Fair enough.. whatever works. What I know is that:

- Many vendors include the minimum number of parts to keep their profit margin higher. (some don't include flanges at all)

- I ordered my 46mm tial directly from TialSport and it came with 3 flanges.

- The bolts had length such that they were too long unless I used 2 flanges on the valve side of the wastegate. At first I thought that I had an "extra" dump flange and then I realized why.. so you don't warp the valve seat when you weld.

- If you take a look further down the page at RoadRaceEngineering (where you got that pic) you'll see that they sell flanges seperately. They list the valve seat flange, and then they list the other flange as "inlet our outlet" flange. I imagine that 3 flanges are what TiAl intended on people using but perhaps to save the extra $40 no one is using them.

- The hardware set for the 46mm gate listed there included 4 20mm bolts and 4 26mm bolts.. that tells me that there's an extra 6mm meant to be bolted up somewhere.. I'd guess it's the extra flange at the inlet.

- TiAl 46's were made to be a direct replacement for a few production cars like porsches, where you wouldn't necessary need the first weld inlet flange as it would be on the exhaust all ready. I could imagine these get sold a lot minus one flange.

- Whatever works. It might be a good question for the suport folks at TiAl.. they're good about getting back to you via email but if it works, who am I to argue?


It is nice to see someone making their own stuff though. Props to you.

..Dave

 

NewburnD is right, you'll need two flanges and the valve seat. When searching for my 46mm tial I had to make sure they included all the hardware, some places sell without the two flanges. In the pic above if you look closely you can see the valve seat and the flange. The flange is coated like the rest of the manifold while the valve seat is shiny

 

yea, I see what you mean now. I will try it this way. if it leaks then I will have to get the second flange and maybe another seat in case it's warped now.

 

It shouldn't leak I've made them both ways just make sure you take your time and weld it right. Get yourself a good piece of thick steel drill four holes and bolt the valve seat to it while you weld it. And don't get too hot you'll be fine. It looks like a good start.