So I started my turbo manifold by doing the flange. 100% self made using a bench drill and a angle grinder.

More pics to follow as project continues.


Modified by Flashmn at 9:17 AM 6/24/2005

 

holy ****! ur crazy!!

 

Thats cool, I like seeing people build stuff!

Best of luck.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote &raquo;</TD></TR><TR><TD CLASS="quote">holy ****! ur crazy!!</TD></TR></TABLE>
How so? :D

 

most people are too chicken to make their own flanges

 

Dude its easier than you might think.

 

Yup, and cheap too

 

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

And that is the best part

 

What head is that? Doesn't look familiar.

 

it looks like a non-vtec D-series head to me.

 

What type of press do you own and whats the thickness of the flange? What type of hole saw did you use?

I have a 3/4 hp 12 inch press and even with a new bimetal hole saw and lubrication, cuts through any mild steel thicker then 3/8th takes forever and a day. I would get upset doing it 4 times over and end up taking it to a mill with the type of press the average person has.

Looks cool so far

 

screw a press (can be done but what a PITA) a mill is the only way to go on something like this.

 

my guess goes to either a AE92 or a 1.6slx head.. most likely the ae92

 

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<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote &raquo;</TD></TR><TR><TD CLASS="quote">my guess goes to either a AE92 or a 1.6slx head.. most likely the ae92</TD></TR></TABLE>

Yup, Toyota Corolla 4A-F head.

 

so what kind of turbo will you be using???, i think you can also use an additional injector controller just install 4 injectors to handle the boosted part of the rev range....

 

I dont know 100% sure what turbo yet, my friend is selling a T28 Garrett from a Diesel VW/Audi, the turbine side is relatively small, but should provide enough air to 200hp. Interesting thing that 4 injectors.. However, wouldnt it be the same if I installed EFI? Just a very basic efi setup.

Or I could use a single injector/jet (N2O fogger etc) to inject fuel before the plenum under boost.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote &raquo;</TD></TR><TR><TD CLASS="quote">What type of press do you own and whats the thickness of the flange? What type of hole saw did you use?</TD></TR></TABLE>
8mm thick, holesaw was an el cheapo "Magnum" one from the local hardwarestore, took maybe 5min per hole. The drill was a Rexon 250A, http://www.rexon.net/product/european/dp-250a.htm

 

Ok I managed to ruin the flange royally, but funny thing is, I have no idea why it went like that. Used normal wire and argon gas

Ok, thats a small test piece I did, weld looks fairly ok...

Now I do the manifold, and it does that!


Penetration in the first weld was good, could see a mark on the other side of the tube, on the manifold, well.. yes theres some, but it looks like bird droppings!

....not to mention whats up with that brown residue.

 

seems like you got some contamination. either form the surface of the metal not being clean enough or you have some bad gas. lol.

 

Yeah talk about bad case of contamination.... yes might be something on the surface, oil maybe?

 

Clean it with acetone. The flange is fine yet, just grind it down.

 

check your gas valve, check your gas. Make sure you're using the right kind. Looks to me that its DEFINETLY A GAS ISSUE.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote &raquo;</TD></TR><TR><TD CLASS="quote">Clean it with acetone. The flange is fine yet, just grind it down.</TD></TR></TABLE>
hahahaha, yeah you should see how warped it is now.... you can see it curve

Gas _should_ be ok. Same **** happened with another bottle.

 

not enough heat....

 

I had the settings on max, I was shooting through the pipe part, but it wouldnt stick to the flange. I played around with power and wire feed settings, but it didnt work out. Gotta try to take a grinder to the flange and see if I can salvage it, then clean it up thoroughly and try again.