I just ordered two flanges from bmcrace.com ( for fast delivery) for the wastegate and dump tube. The problem is that my equal length turbo manifold has a 40mm flange welded on and I was wondering what is the best way to cut off that flange so I can grind it flush and reweld the 38mm flange. There is also a groove that is machined in the flanges I ordered and I was wondering if it would be a slip fit type of deal before getting welded or does it just get welded flush against the surface of the flange. Also I want to confirm that the position of the wastegate flange should have the dump tube pointing down so that way I won't have it positioned the wrong way and re-work the part, thanks.

Here's a couple pictures


from what I've been told this is a Spark Racing manifold for b series applications due to it having a merge collector and the head flange shape. I have the turbo mounted backwards I know..


can you see the groove?




me at work, fun stuff.


Modified by damnraz at 7:46 PM 2/6/2006

 

bump! need to know asap

 

uses a handheld saw of somesort, sawzaw,air compressed saw bit etc.. Then clean the hell out of it when your done. Btw MAKE SURE ITS EVEN! I made that mistake on a manifold once and boy was it hard to weld it. good luck!

-Jon

about your dumptube, point it facing downwords but dont face it towards any wires, or things that hot *** exhaust gas would harm.

 

The groove is to retain the sealing ring from the wastegate, isn't it?

 

the retaining ring already sits flush with the groove positioned outward shown in the picture above, I don't have a pair of calipers with me to check the dimensions at home but I think the retaining ring might be about .040-.050 thousandths in length and the groove shows a lot more than .040-.050 thou clearance. I don't know.. this is the first time I've worked on a project for my car, but thanks to SMS-Fab for tips.

Beepy, I've read a lot of your posts and you're an Mechanical Engineer?, that's good stuff, maybe you can help me with my welding projects and all, still basically learning but for right now and want to tackle a couple projects, I'm a CNC tube bender at an aerospace company, but I had practice with TIG and all and the only thing I've known how to weld is thin wall CP-TI and TI-6AL4V, also know how to fit parts to very close tolerances.

 

I havse that same manifold and i have the same problem .. with my 38 mml tial let me know u u work things out man