...I'm still not sure why the other thread was locked, but lets try this again. For those of you who will get their panties in a twist, I AM NOT SELLING THESE YET, AND THIS IS NOT AN ADVERTISEMENT! . If you think it is, go look up the definition of advertisement, and have a nice day. Just like the first thread, I am mearly intending this to be a technical thread about the manifold.

We'll I have put a lot of thought and time into this design, so I'm happy to finally have a working prototype. I'd like to thank the following people for making this happen:

Servion, and his wife for giving me the opportunity to build this!
Rich at Ace stainless
RLD-fab for the advice and great collectors
Sam at BMC race
Brent at PFI (thanks again for the late night filler!)
RedZCstandardhatch for the rad info!

The background on this manifold: Well it was originally intended for the sole purpose for the EF chassis, but after building it, I realized that it's just a tad bit larger than what I planned. It should fit perfectly in an EG, but it has some hood clearance issues in my CRX. Even with my VIS SIR hood, it pushes the hood up about 1". I think I will offer the manifold with the smaller radius els for the 1st and 2nd runners to fit the EF chassis. It will also require a scirroco style radiator setup in an EF, because the runners stick so far out.

The benefits, and goals of this manifold: simply put... 40R fitment with little to no chassis mods, a single WG prioritized collector (say good buy to creep and spiking issues!), and tons of DP clearance (5" is possible). The turbo placement is perfect for a back door IC style setup, and also mounts the turbo high enough for a decent drain line. This style of collector arrangement also allows someone to utilize the new V band style of exhaust housings available from Tial. When it came down to designing this, I wanted to make sure it was a well rounded piece that could be applied to most setups.

Now for the pics:




















Thanks for looking!
I am VERY interested in hearing what people think, so any comments are welcome!

Bryson

 

From the other thread...

"That tube fits up to the opening of the t3 flange terrible, and it doesn't seem to fit up to the collector very good either. Let's not forget the basics of what this piece is designed to do, smoothly transfer air from the head to the turbo. I'd step down the elbow after the collector to something that properly fits up to the T3 flange. Congrats on building something different though."

 

Oh, and it obviously wasn't backpurged at the tube to turbine inlet flange, was the rest of it?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">From the other thread...

"That tube fits up to the opening of the t3 flange terrible, and it doesn't seem to fit up to the collector very good either. Let's not forget the basics of what this piece is designed to do, smoothly transfer air from the head to the turbo. I'd step down the elbow after the collector to something that properly fits up to the T3 flange. Congrats on building something different though."

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

Actually it fits pretty good. I need to port the flange of course, but it won't be a problem. It's funny to me how you say this now, as to this is the exact same el that RLD used on his project car, yet you didn't mention anything about that. Also this is the first manifold of this type I've made, so of course the fitment could be a little better, and will continue to get better as I make them.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">Oh, and it obviously wasn't backpurged at the tube to turbine inlet flange, was the rest of it?</TD></TR></TABLE>

Obviously. I havn't really designed a method yet as to how to backpurge the collector el assembily, but I'm working on it. However, the rest of the manifold was.

I appreciate your input Tony.

 

Actually, might want to check that post again, i said the exact same thing to him. Porting the collector is still going to give it a very excessive angle there, why not just use the right pipe? Don't you think that is going to affect the performance having the collector dump into such a big pipe before the turbo?

How do you not have a "method" to backpurge the end part? Aluminum foil and some tape, not really much of a method to it. Any inside pics of the runners, at the back side of a weld perhaps?

 

Yes on the s2000 I welded in some of the lip and went at it with a carbide , it took some time , but I think I crushed mine more to fit the flange better , also the end of that collocter was angle cut so the opening was not round any more so I hade to crush that end also , but not bad for the first one and only needed to fix some small things and you will find the dollar store is great for all the tin foil you need

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">Actually, might want to check that post again, i said the exact same thing to him. Porting the collector is still going to give it a very excessive angle there, why not just use the right pipe? Don't you think that is going to affect the performance having the collector dump into such a big pipe before the turbo?

How do you not have a "method" to backpurge the end part? Aluminum foil and some tape, not really much of a method to it. Any inside pics of the runners, at the back side of a weld perhaps?</TD></TR></TABLE>

I could have sworn you only told him to port the flange, but whatever. The reason I chose this pipe, is because it will also fit the T4, and 2.5" Vband flanges. No I don't have pics.

 

He said his was 3/32" over the opening, yours is way more than that. I can't say if his 3/32" is correct or not, he never showed the inside, but you can clearly see the inside of yours.

For what it's worth, my opinion is you don't use the wrong size pipe for T3, just so it'll fit a T4. You use the right size for each application.

 

pics look pretty good man..

tallkyle called me wondering what the rad info i gave you was! haha..radiator, not rad.

good job man, looks like a good start to what could be a different and power-producing design

 

I give you props bro, becasue I know how much time and effort goes into it. Good luck with the rest of the setup! I like it.

 

what i like about the design is the room you have for the dp and the simple backdoor access for the intercooler. nice work.

 

Its new and its got a few things that need taken care of which tony already brought up, glad you built something different than whats out on the market already..

Now make a gt42 fit in there

 

i'm sure bryson will make it flow nicely inside...he seems to know a bit about making power..

prototype FTW..good luck man.hope it throws down some big numbers

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Boostwerks.com &raquo;</TD></TR><TR><TD CLASS="quote">after building it, I realized that it's just a tad bit larger than what I planned.
</TD></TR></TABLE>

With the first manifold I designed (in CAD) I quickly realized that it would have went though my hood and bumper when I started to mock it up.

Trial and Error.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">He said his was 3/32" over the opening, yours is way more than that. I can't say if his 3/32" is correct or not, he never showed the inside, but you can clearly see the inside of yours.

For what it's worth, my opinion is you don't use the wrong size pipe for T3, just so it'll fit a T4. You use the right size for each application.</TD></TR></TABLE>

Do you think the 2" el would form better? I think the 2.5" should fit perfectly when it is formed to the rectangular inlet of the flange. I will definetly be doing this in the future, and would have done it here, but i didn't have any means to squish the pipe. (I'll admit it...i don't own a vise )

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by weiRtech &raquo;</TD></TR><TR><TD CLASS="quote">what i like about the design is the room you have for the dp and the simple backdoor access for the intercooler. nice work.</TD></TR></TABLE>

Exactly. it makes building the supporting equipment (DP, backdoor, drain line, and even feed line) so easy. I figured it would work best if the manifold placed the turbo in an ideal location, to support the ideal supporting equipment.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Adi Radoncic &raquo;</TD></TR><TR><TD CLASS="quote">Its new and its got a few things that need taken care of which tony already brought up, glad you built something different than whats out on the market already..

Now make a gt42 fit in there </TD></TR></TABLE>

Honestly, the 42 might even fit in there already. I don't have one on hand to be 100% sure, but from the dimensions that I have received, it might. The 40R on the other hand I know will fit without question.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by redzcstandardhatch &raquo;</TD></TR><TR><TD CLASS="quote">i'm sure bryson will make it flow nicely inside...he seems to know a bit about making power..

prototype FTW..good luck man.hope it throws down some big numbers</TD></TR></TABLE>

thanks man, and of course I'll be addressing those issues. Theres not a single prototype on the planet that comes to being close to perfect the first time out...but It'll get there.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 2point2 &raquo;</TD></TR><TR><TD CLASS="quote">With the first manifold I designed (in CAD) I quickly realized that it would have went though my hood and bumper when I started to mock it up.

Trial and Error. </TD></TR></TABLE>

Exactly. I was only able to get my hands on solidworks inventor just recently from my employeer, but if I had the software I would have definetly used it before building one. I'd like to consider mysef as a decent hand drafter, so I just used my measurements to make a somewhat educated guess as to how it would look and fit. I knew it was going to be close, but it looks like I'll have to tweek the design some to get a reliable fitment in the EF chassis.

 

Pretty easy to figure out, what's the i.d. of the 2" and the 2.5" pipe? Go take a piece of paper and roll it up to that size and see which fits better. The one you used is too big all the way around, i don't see it shaping to fit that hole very easily. For what it's worth, i used a transition from burns on the evo header i did, it was a 2.25" o.d. tube to a T4 flange.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">

How do you not have a "method" to backpurge the end part? Aluminum foil and some tape, not really much of a method to it. Any inside pics of the runners, at the back side of a weld perhaps?</TD></TR></TABLE>

I have been using the aluminum foil method on the runners, but I havn't come up with something that works well on the collectors and that el. The aluminum foil tends to fall off, and leak as I am welding it. I am also using a seperate argon tank for the sole purpose of purging, and using a valve setup to trigger the gas. This is the method I'm refering too, and there must be a better more effective way of doing this. I've been meaning to make a thread to ask this very question.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">Pretty easy to figure out, what's the i.d. of the 2" and the 2.5" pipe? Go take a piece of paper and roll it up to that size and see which fits better. The one you used is too big all the way around, i don't see it shaping to fit that hole very easily. For what it's worth, i used a transition from burns on the evo header i did, it was a 2.25" o.d. tube to a T4 flange.</TD></TR></TABLE>

I'll get a 2" el and see how it forms up to the flange.

 

I like it Bryson. Nice design.

 

would have been nice to see the turbo braced to the block instead.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 743power &raquo;</TD></TR><TR><TD CLASS="quote">would have been nice to see the turbo braced to the block instead. </TD></TR></TABLE>

I agree actually. I might be making a bracing kit to go along with the manifolds. The only problem is that I would need to develop one that would work with a variety of different turbo's.

 

What's the difference, if the mount is solid? The mount needs to support the weight of the turbo, but still allow the manifold to expand and contract with heat. Anything solid will not do that.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">What's the difference, if the mount is solid? The mount needs to support the weight of the turbo, but still allow the manifold to expand and contract with heat. Anything solid will not do that.</TD></TR></TABLE>

Thats exactly why I choose to put the solid mount where I did. However, the braces that I was talking about would utilize a double ended heim joint to allow the turbo/manifold assembily to move slightly with normal expansion/contraction. That way it's not putting a single load point on the runners. F1's FTW

But I don't think we'll see any problems with it braced how it is.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">What's the difference, if the mount is solid? The mount needs to support the weight of the turbo, but still allow the manifold to expand and contract with heat. Anything solid will not do that.</TD></TR></TABLE>

ever see an f1 motor on the engine dyno? manifolds move up to 5"

those manifold builders are amazing

 

That's how my manifolds are, so far on the evo, a lot of street driven miles, and a very violent anti lag setup, over a year now and no cracks, 16ga. 321 stainless.