didnt know which sub forum this thread was better suited to. (Welding fab or forced induction) so i thought i'd post in both.
1 problem with USDM parts, and getting them to fit on UKDM/JDM cars is the obvious LHD/RHD differences.
This difference was a problem with the Full-Race ram horn turbo kit for the s2000 that the customer purchased for his vehicle.
The brake booster, steering column and abs unit fouled the ram horn manifold on his JDM s2000, which meant the turbo kit took a back seat in his closet until a RHD kit was made. 1.5 years later, he couldn't wait no more, and so went in search of a custom turbo kit. most places booked him in, and kept on rebooking him, as they were swamped with work. Annoyed by that fact, he asked if we (angel-works) could turbo his car.
We agreed to take on the project, and collaborated with Solid-fabrications. And in 2 days, we have designed and mocked up a sidewinder bottom mount manifold, 3 inch downpipe and exhaust, and boost piping. There are a few things left to do, (wg, bov, weld everything together) but the major components are in place.
Apologise for the fone camera pics, will be getting better pics taken once the manifold is complete.
The original design was to go with a sidewinder top mount setup, ala inline pro/love-fab, but then that wouldnt allow a 3 inch dp, as they dont have the steering column to contend with. Being a bottom mount, angling the turbo at 45degrees, or there about wasnt gonna be easy, especially trying to turn the 3 inch downpipe around the vtec solenoid and oil filter.
heres a few pics of the kit being made.
making a temporary jig to hold the turbo where we want it.
20 hours later and the manifold, dp, exh system, boost piping is done. i did take pics of the process inbetween, but thought i'd load the best pics.
heres some pics of the turbo kit on a mock engine we had lying around.
we ran out of straight sch10, and had to make do just to get the manifold complete, but the long section on no4 will be gettin replaced.
heres pics of the turbo brace/manifold support
another triangular gusset will be added for further support.
the collector clears the bonnet/hood with about 10mm to spare. an oil filter relocator will be needed with this kit.
best of all, a 4 inch d/p will fit aswell, but the customer specified a 3 inch dp and exh.
the turbo hangs 7mm from the chassis cross beam, and theres lots of space for the wastegate.
best of all, there are only 2 boost pipes, suprisingly, you can manoeuvre the boost pipes into place, even though they are such long weird shape pieces.
material used:
sch10 3mm for the manifold
1 problem with USDM parts, and getting them to fit on UKDM/JDM cars is the obvious LHD/RHD differences.
This difference was a problem with the Full-Race ram horn turbo kit for the s2000 that the customer purchased for his vehicle.
The brake booster, steering column and abs unit fouled the ram horn manifold on his JDM s2000, which meant the turbo kit took a back seat in his closet until a RHD kit was made. 1.5 years later, he couldn't wait no more, and so went in search of a custom turbo kit. most places booked him in, and kept on rebooking him, as they were swamped with work. Annoyed by that fact, he asked if we (angel-works) could turbo his car.
We agreed to take on the project, and collaborated with Solid-fabrications. And in 2 days, we have designed and mocked up a sidewinder bottom mount manifold, 3 inch downpipe and exhaust, and boost piping. There are a few things left to do, (wg, bov, weld everything together) but the major components are in place.
Apologise for the fone camera pics, will be getting better pics taken once the manifold is complete.
The original design was to go with a sidewinder top mount setup, ala inline pro/love-fab, but then that wouldnt allow a 3 inch dp, as they dont have the steering column to contend with. Being a bottom mount, angling the turbo at 45degrees, or there about wasnt gonna be easy, especially trying to turn the 3 inch downpipe around the vtec solenoid and oil filter.
heres a few pics of the kit being made.
making a temporary jig to hold the turbo where we want it.
20 hours later and the manifold, dp, exh system, boost piping is done. i did take pics of the process inbetween, but thought i'd load the best pics.
heres some pics of the turbo kit on a mock engine we had lying around.
we ran out of straight sch10, and had to make do just to get the manifold complete, but the long section on no4 will be gettin replaced.
heres pics of the turbo brace/manifold support
another triangular gusset will be added for further support.
the collector clears the bonnet/hood with about 10mm to spare. an oil filter relocator will be needed with this kit.
best of all, a 4 inch d/p will fit aswell, but the customer specified a 3 inch dp and exh.
the turbo hangs 7mm from the chassis cross beam, and theres lots of space for the wastegate.
best of all, there are only 2 boost pipes, suprisingly, you can manoeuvre the boost pipes into place, even though they are such long weird shape pieces.
material used:
sch10 3mm for the manifold
Solid-Fab got the materials in to make the jig, so mass production can start if there is a demand.
heres a few pics
with the jig made, the manifold can be taken apart to be welded up properly.
the turbo flange and the dp flange were bolted to a solid ally plate to prevent warping whilst welding.
waiting on more sch10 piping to finish the rest of the manifold off.
stay tuned for more updates
heres a few pics
with the jig made, the manifold can be taken apart to be welded up properly.
the turbo flange and the dp flange were bolted to a solid ally plate to prevent warping whilst welding.
waiting on more sch10 piping to finish the rest of the manifold off.
stay tuned for more updates
HT White Ops
Quote:
Originally Posted by K7-1Ktrevor
whats the foil for?
back purging
Honda-Tech Member
Quote:
Whats back Purging?Originally Posted by SD_Lurker
back purging
Honda-Tech Member
Someone is going to be a very proud owner.
Some workers are going to be very proud of their abilities.
Some workers are going to be very proud of their abilities.
Honda-Tech Member
back purging means they purg the pipe with 100% argon so the pipe doesent sugar up on the inside...
Honda-Tech Member
Quote:
Oh. Sweet. Thanks.Originally Posted by laosonick
back purging means they purg the pipe with 100% argon so the pipe doesent sugar up on the inside...
manifold's pretty much done now.
close up of the welds
close up of the welds