Tinker219

Im wondering how to cut each primary to make a collector. So far I have gotten by with just using plates to mate the primaries to the turbo flange but that is ghetto and not as functional.
I need to find out how to cut each individual tube, so that all 4 primaries meet without any gaps...
I looked at the BurnsStainless design(my eventual goal) and I have a general Idea, but I want to see what anyone else has to say...

legendboy

it really needs to be done by some kind of cnc. Either plasma or water cut, milling... Thats how the full race ones are made I think.

Overblown-Teg

a good band saw works very well. What kind of material are you using?

Tinker219

I will be using stainless and mild steel...im making a few for me and some friends, and the square design isnt cutting it anymore....
ill get whatever needs to be done with the good ol sawzall...i just need to know what shape to cut the tubes in....

The Mick

Hey Tinker219,
I've thought about this a little bit recently. It seems like I remember 15° (included angle) for the transition from tubes to the collector, but I'm not sure if that's the ideal angle or not. I'll be doing mine on a Bridgeport milling machine for neatness and accuracy, but I'm sure the same could be done on a nice belt sander or band saw. Assuming the 15° thing above, I'd put one of the primaries into the vise at approximately 7.5° from horizontal and mill it. Then rotate the tube 90° in the vise and make the same cut. If I'm thinking right, doing all 4 primaries this way would make for a good fit and leave the desired "cone" shape inside where the 4 pipes meet. I haven't attempted this yet, but I think should work.
Let us know how yours turn out. Good luck!
Mick

Overblown-Teg

your never going to cut schedule 40 stainless with a sawzall. Get a nice big band saw with a 3/4" wide blade. Also pretty much use what ever angles work for the piece your making. To figure out how much to cut off each side, Start with two. measure the inside of the flange. then from inside to outside on the pipes. Add the two pipes together and subtract by the flange opening. then divide that number by two. That is how much you need to cut from the end of the pipe. The rest is just getting the angle. After you cut those two do two more so you have all four. Then measure the other opening size and do the same thing.

Tinker219

These are big ticket items are they not? anything over $100 is big for me right now.
as for Mick, I have limited access to a Bridgeport(I work summers at a machine shop) but Im not sure how long I would have to work on it. My first attempt will be out of mild steel, so that its welded easily, cuts easily, and most of all is cheap...

Overblown-Teg

Tinker.. Most of them are around $1000 for the saws.. Unfortunatley its pretty much the only way to do it and have it turn out nice. I'm just trying to help you out here. I tried it with a lower end band saw and the blade deflects too much for a nice fit. Also tried a plasma cutter and there is too much clean up time and its not presise enough.

Tinker219

ya i figured about a grand. Hey i know, I could sell my car, buy all these sweet tools, and then make manifolds for a living....
ive made 5 already...why not keep going...

Overblown-Teg

heh.. the tools would pay for them selves pretty quickly if you can keep selling manifolds.

Tinker219

Ive only sold one and that was in-trade for some parts.
Ive had about ten people flake on me though, understanding because none of my work has been recognized yet....im workin on it though.
oh ya, I just dropped $1700 on a Lincoln Squarewave 175, so Im pretty broke now