My first turbo manifold! Pic intensive!
03-13-2009, 11:13 AM
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My first turbo manifold! Pic intensive!
I've had my dynasty 200 for about 7-8 months now but I have not been welding nearly that long. I took a class at my community college for about 2 weeks and then decided I would just do it at home when I got the welder. I have not had many projects to practice on other than a little exhaust work, my welding table and my intercooler before this. I just sold my turbo and manifold because I want to to build one so I then had no choice but to take the challenge. My plan was to copy the full-race top mount design!
Collector. I actually pick this up from SLS because I spent at least 6 hours practicing on pvc pipe and I had no luck LOL!
First runner done and starting on the second. See my retarded jig! I eyeballed the location and just went with it.
Second runner done. One piece did not line up at that well.
A test fit in the car although it would have been a little too late if it did not fit since I had a few hours on it already. Looked good so far!
Back on out and finished the 3rd runner. I was pretty damn impressed how good it was looking now!
Turbo sitting on top...
I picked up another tank of gas and started and finished the last runner last night. I did not break any of the runners off to weld them up. I should have because some areas specially around the collector were such a pain.
and I started on the head flange too!
I went to home depot and bought a hole saw for the wastegate elbow so I'll be working on that tonight and I will start on the downpipe. Wish me luck! LOL
What do you guys think?
PS- I also realized that I am a lot more steady with the torch on my left hand. I can feed the filler more comfortably with my right hand, maybe because I am right handed, LOL
Collector. I actually pick this up from SLS because I spent at least 6 hours practicing on pvc pipe and I had no luck LOL!
First runner done and starting on the second. See my retarded jig! I eyeballed the location and just went with it.
Second runner done. One piece did not line up at that well.
A test fit in the car although it would have been a little too late if it did not fit since I had a few hours on it already. Looked good so far!
Back on out and finished the 3rd runner. I was pretty damn impressed how good it was looking now!
Turbo sitting on top...
I picked up another tank of gas and started and finished the last runner last night. I did not break any of the runners off to weld them up. I should have because some areas specially around the collector were such a pain.
and I started on the head flange too!
I went to home depot and bought a hole saw for the wastegate elbow so I'll be working on that tonight and I will start on the downpipe. Wish me luck! LOL
What do you guys think?
PS- I also realized that I am a lot more steady with the torch on my left hand. I can feed the filler more comfortably with my right hand, maybe because I am right handed, LOL
Last edited by champLSinteg; 03-13-2009 at 11:42 AM.
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03-13-2009, 12:04 PM
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Re: My first turbo manifold! Pic intensive!
Looks damn good man!
03-13-2009, 12:08 PM
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Re: My first turbo manifold! Pic intensive!
03-13-2009, 04:17 PM
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Re: My first turbo manifold! Pic intensive!
looks really good for your first one. I'm ambidextrious and I cannot for the life of me feed filler right handed. Fusion welding left handed? hell yeah I can do that just as good with either hand. Put a piece of filler in my right hand and my god it's like time traveling back to when I first started welding lol. Bugs the hell out of me.
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03-13-2009, 05:17 PM
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Re: My first turbo manifold! Pic intensive!
looks really good for your first one. I'm ambidextrious and I cannot for the life of me feed filler right handed. Fusion welding left handed? hell yeah I can do that just as good with either hand. Put a piece of filler in my right hand and my god it's like time traveling back to when I first started welding lol. Bugs the hell out of me.
Thank you all for the compliments!
03-16-2009, 07:50 AM
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Re: My first turbo manifold! Pic intensive!
Update!! Lot more pics! Enjoy!
I picked up a hole saw and got the wastegate done.
I then threw it in the car to mock up the downpipe to mate with my exhaust.
Took it back out and put it on the mock up motor to start on the dump tube.
Dump tube done!
And here it all is in the car! I am so excited! I pat myself on the shoulder! LOL
Now I have to do the hot side charge pipe. I should be cake though!
I picked up a hole saw and got the wastegate done.
I then threw it in the car to mock up the downpipe to mate with my exhaust.
Took it back out and put it on the mock up motor to start on the dump tube.
Dump tube done!
And here it all is in the car! I am so excited! I pat myself on the shoulder! LOL
Now I have to do the hot side charge pipe. I should be cake though!
03-16-2009, 09:04 AM
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03-16-2009, 11:55 AM
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Re: My first turbo manifold! Pic intensive!
nice job..very nice job for the first one. I'm on my third manifold now, all it takes is time and practice, which I never have enough of!!
03-16-2009, 12:21 PM
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Re: My first turbo manifold! Pic intensive!
Thanks! Now that I am done I know I can do it a little quicker and with practice definately even more quick. I cut everything with a chop saw because the blade on my HF bandsaw broke on the second cut into it. All the deburring, wire wheeling, and beveling took forever though! LOL but it does pay off in the end.
03-16-2009, 12:23 PM
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Re: My first turbo manifold! Pic intensive!
Definitely kind of an unorthodox method of building the manifold, but it worked out for the mostpart. You've learned alot from the first, and that'll translate to any others if you build more.
Jigs are a big part of being successfull, and they are certainly better ways to build the mani versus how you did it. You don't really want to weld up runners prior to building others, especially on tight fitting or more complex designs.
You want to establish a strong jig, mock up the entire mani, then disassemble and weld certain runners at a time to allow yourself the most torch room and access to the collector.
Lastly, the best advice I can give you after your first manifold, is don't decide to start a business making Honda manifolds.
Jigs are a big part of being successfull, and they are certainly better ways to build the mani versus how you did it. You don't really want to weld up runners prior to building others, especially on tight fitting or more complex designs.
You want to establish a strong jig, mock up the entire mani, then disassemble and weld certain runners at a time to allow yourself the most torch room and access to the collector.
Lastly, the best advice I can give you after your first manifold, is don't decide to start a business making Honda manifolds.
03-16-2009, 01:01 PM
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Re: My first turbo manifold! Pic intensive!
Definitely kind of an unorthodox method of building the manifold, but it worked out for the mostpart. You've learned alot from the first, and that'll translate to any others if you build more.
Jigs are a big part of being successfull, and they are certainly better ways to build the mani versus how you did it. You don't really want to weld up runners prior to building others, especially on tight fitting or more complex designs.
You want to establish a strong jig, mock up the entire mani, then disassemble and weld certain runners at a time to allow yourself the most torch room and access to the collector.
Lastly, the best advice I can give you after your first manifold, is don't decide to start a business making Honda manifolds.
Jigs are a big part of being successfull, and they are certainly better ways to build the mani versus how you did it. You don't really want to weld up runners prior to building others, especially on tight fitting or more complex designs.
You want to establish a strong jig, mock up the entire mani, then disassemble and weld certain runners at a time to allow yourself the most torch room and access to the collector.
Lastly, the best advice I can give you after your first manifold, is don't decide to start a business making Honda manifolds.
I dont plan on making this manifold again but I now realize that the jig is what keeps everything together. I dont plan on making this a business but if I do I definately will not be honda specific! LOL I read a lot on hear from you and others that there is no money making honda manifolds!
03-16-2009, 11:46 PM
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Re: My first turbo manifold! Pic intensive!
Yeah, absolutely on the dremel. I construct and tack runners in a location I can reach with a dremel and cutoff and remove tacks when needed. Once mocked up, you can remove whatever runners you want and weld them in place (except for the head and collector joint) then remove them when cool. Insert others, weld, remove, etc. IF your jig is strong, you can reassemble and weld to the head flange and collector in the order that's easiest. The jig must be strong though to avoid issues.
03-17-2009, 01:44 AM
#22
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Re: My first turbo manifold! Pic intensive!
amazing job for such little time on the tig machine !
only part i didnt like, was your front bumper sitting on the roof of your ride
only part i didnt like, was your front bumper sitting on the roof of your ride
03-17-2009, 06:27 AM
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Re: My first turbo manifold! Pic intensive!
Yeah, absolutely on the dremel. I construct and tack runners in a location I can reach with a dremel and cutoff and remove tacks when needed. Once mocked up, you can remove whatever runners you want and weld them in place (except for the head and collector joint) then remove them when cool. Insert others, weld, remove, etc. IF your jig is strong, you can reassemble and weld to the head flange and collector in the order that's easiest. The jig must be strong though to avoid issues.
I had my amperage set around 130 pretty much the whole time but I almost never had the pedal maxed out. I got the pipe and tubing from acestainless, turbo and head flange from SLS and all the other flanges from ATP. ATP is 5 mins from my house!