liam821

So this is more of an ::emo:: post more then anything else. My manifold cracked again yesterday after a saturday drive in the country. This will be the 2th time. Always cracks in the same place. Right around where the wastegate connectors to the manifold. Another hour of work to pull the manifold off, reweld the damn thing, and put it back on.



I was driving to goto dinner with a friend on saturday night, and i hit a little bump in the road and the car got reaalllyyy loud. I pulled over and the wastegate was hanging there by the vacuum lines. Its never cracked all the way until it broke off like that before.

Im sure i can get it fixed but argh its annoying.

old picture...


So today i started saving for something new...a manifold even more crazy then what i have now. Im also going to replace my 60trim turbo with something bigger. And i see a 5bar map sensor in my future...

liam


Modified by liam821 at 3:34 AM 3/21/2005


Modified by liam821 at 5:31 PM 3/27/2005


Modified by liam821 at 5:31 PM 3/27/2005

Tad

Haha,
sorry to laugh but it's funny.

someone will probly talk smack, but ****,
i'd say it's worth it to have a wg falling off when you have a mani that looks that freakin cool!!

But hey, why don't you just weld on a darned support! I mean really!
Probably don't even need to add much.

Bigger turbo now eh?
How much power do you think that built ZC can really handle?

Sunlight

Hi Liam21,

Do you have any specs for your turbo and what brand it is?
Looks like a turbonetics to me.

Thanks

USDM 4G VTEC

a 5 BAR MAP sensor?
HAHAHAHA
unless u have a Supra motor in there or other sort of engine that can handle like 25psi or more... a 5 BAR map sensor is stupid..
i bet he only wants to say heh has a 5 BAR sensor..
i have a 2.5 BAR and i know i am not going to even max it out.. because i am realistic and know what it involves and what it takes to push that kind of power

monicle

sounds like its time to get a worthwhile manifold. also are you actually running a dump tube or ar you just letting that soot and crapp go floating around in your engine bay?

buckfittyone

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by USDM 4G VTEC &raquo;</TD></TR><TR><TD CLASS="quote">a 5 BAR MAP sensor?
HAHAHAHA
unless u have a Supra motor in there or other sort of engine that can handle like 25psi or more... a 5 BAR map sensor is stupid..
i bet he only wants to say heh has a 5 BAR sensor..
i have a 2.5 BAR and i know i am not going to even max it out.. because i am realistic and know what it involves and what it takes to push that kind of power</TD></TR></TABLE>
or maybe he is actually 'pushing that kind of power' and actually needs one

Ekasey

Maybe you should try fabricating a brace so all of the stress isn't put on the weld joint there. Wastegates way a decent amount

Si Shane

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLusive ek4 &raquo;</TD></TR><TR><TD CLASS="quote">Maybe you should try fabricating a brace, so all of the stress isn't put on the welded joint there; wastegates weigh a decent amount! </TD></TR></TABLE>

Elusive ekedit

m R g S r

brace from the turbo flange to the WG to the tranny (if there isnt already a brace from the tranny to the turbo flange)

Enzo-Racing

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by eLusive ek4 &raquo;</TD></TR><TR><TD CLASS="quote">Maybe you should try fabricating a brace so all of the stress isn't put on the weld joint there. Wastegates way a decent amount </TD></TR></TABLE>

I agree...

Also maybe add a v-band to allow a little bit of flex.
If built properly and braced correctly you shouldn't have a problem with thin wall stainless(16ga).

liam821

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Tad &raquo;</TD></TR><TR><TD CLASS="quote">Haha,
sorry to laugh but it's funny.

someone will probly talk smack, but ****,
i'd say it's worth it to have a wg falling off when you have a mani that looks that freakin cool!!

But hey, why don't you just weld on a darned support! I mean really!
Probably don't even need to add much.

Bigger turbo now eh?
How much power do you think that built ZC can really handle?</TD></TR></TABLE>

It is pretty funny - thats why i posted it.

I thought about welding in a brace for the wastegate, but it connects so close to the manifold im not sure how or where to build it in. I suppose i could come up with something. I guess ill see if i can make a brace. And yeah vibration from the motor just shakes the wastegate until the manifold cracks.

Im not sure how much power it can handle....but i think it will hold together with 35-37psi of boost tho. As long as the tuning is good. I guess we'll find out huh? Worst thing that will prolly happened is ill blow a headgasket or melt a piston. I dont think i could break a rod (i run Crower Billet I-beams), and the block is sleeved. What else can happened right? hehe

As for engine management, im currently running a Neptune with a 3bar. I havent gotten around to getting on the dyno to testing 28-29psi yet - just havnet had time. Ill have my tuner there when i retune for highboost like that.

Give me a few months to save up some cash - and then ill make it happened.

liam

liam821

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by sunlight &raquo;</TD></TR><TR><TD CLASS="quote">Hi Liam21,
Do you have any specs for your turbo and what brand it is?
Looks like a turbonetics to me.

Thanks</TD></TR></TABLE>

Its a Garrett t3/t04e 60trim with a .63ar stage3 hotside. Has the 4 bolt bolistic flange. It came in a big garrett box.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by slow poke &raquo;</TD></TR><TR><TD CLASS="quote">It says right in his sig:
380whp/280torque @ 24psi race gas
He will need a 5 bar if be goes past 30psi.
BUT he said a new turbo is in the works so I really doubt he will end up running 30+ Psi.
30psi and 400HP = Needs a bigger turbo</TD></TR></TABLE>

The 60trim just isnt very efficient past 23-24psi of boost. To really make good power on the d-series you need to push alot of boost through the motor. A gt35R wheel is the way to go with that motor. However to make it actually spool it you need to have a small exhaust side. The turbo will be like a smaller version of say the full-race t67/t3 - but using the gt35R wheel. Innovative turbo said they would cook up a nice little something something.

liam

wantboost

iTrader: (2)

hey, liam.. pm'd ya

mrDFWmechanic

damn that **** broke right off ... just try to fab somethin else instead of it just hanging there. would've sucked it if fell off then you'd have to buy a new one

liam821

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by iROCKtheSOHC &raquo;</TD></TR><TR><TD CLASS="quote">damn that **** broke right off ... just try to fab somethin else instead of it just hanging there. would've sucked it if fell off then you'd have to buy a new one</TD></TR></TABLE>

It did fall off - it was hanging by the vacuum lines...haha

liam

Enzo-Racing

double up on the material where the wastegate pipe meets the manifold.
Otherwords make gussets to hold it together. Adding material will make it stronger. Just use strips of s/s tubing (same as what your using now) and add them over the already welded area. This should help out greatly...

turboEGhatch

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by USDM 4G VTEC &raquo;</TD></TR><TR><TD CLASS="quote">a 5 BAR MAP sensor?
HAHAHAHA
unless u have a Supra motor in there or other sort of engine that can handle like 25psi or more... a 5 BAR map sensor is stupid..
i bet he only wants to say heh has a 5 BAR sensor..
i have a 2.5 BAR and i know i am not going to even max it out.. because i am realistic and know what it involves and what it takes to push that kind of power</TD></TR></TABLE>

Thumbs up for ignorance

TurboJesse

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by turboEGhatch &raquo;</TD></TR><TR><TD CLASS="quote">

Thumbs up for ignorance </TD></TR></TABLE>

I agree...Because only supra motors can handle 25psi..(whatever that means)

0project dc2

iTrader: (1)

stop rewelding the same piece. cuz you just heat cycle it everytime and the metal gets brittle. replace the piece with a new piece of stainless. preferrably 321 if you're gonna use thin walled stuff. grind off the old stuff etcc. make a brace should hold up well. once something cracks it hard to reweld it and keep the same reliabiltiy as it once had. each time you weld it it just gets weaker.

integlspwr2k

iTrader: (3)

like elusive said, please brace the wg..

trentepic

use a cast side winder!
heck u can make it work on the d seris i think....
-Toby

liam821

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by USDM 4G VTEC &raquo;</TD></TR><TR><TD CLASS="quote">a 5 BAR MAP sensor?
HAHAHAHA
unless u have a Supra motor in there or other sort of engine that can handle like 25psi or more... a 5 BAR map sensor is stupid..
i bet he only wants to say heh has a 5 BAR sensor..
i have a 2.5 BAR and i know i am not going to even max it out.. because i am realistic and know what it involves and what it takes to push that kind of power</TD></TR></TABLE>

You obvously have no idea what you are talking about. There are lots of people here on honda-tech which use 5bar map sensors and boost more then 30psi of boost. I almost max out a 2.5bar map sensor on a daily basis on pump gas. A well thought out honda motor can easily handle 30+psi of boost.

Id like to believe ive covered my bases and did just that.

liam

Tad

i think he thinks ur zc is stock,

HAH!!

liam821

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Tad &raquo;</TD></TR><TR><TD CLASS="quote">i think he thinks ur zc is stock,

HAH!!</TD></TR></TABLE>

haha yeahhhh...its all stock.