hey...

i just finished up my first serious turbo manifold... and i would like some comments from the pro's

first pass was 35-40 amps without filler
second pass was 45 amps with filler..
backpurged the entire time with pure argon gas...

trying to get the right colors and shiny welds



how does it look?

 

hmm... wrong section... can someone move this?

 

I'm also from Holland. On which car is this going?

 

on a red b16 del sol...


this one... the header is a replacement of the xspower ramhorn he had now... it cracked obviously...

 

good stuff man...look real nice

 

Moved to the Welding/Fabrication forum

You'll get better answers here...the FI Forum is more for FI related questions; whereas, this forum is all fab related stuff. Good work on the ramhorn btw

 

thnx...

 

That's the Del Sol from Theo;-)
Off topic: How far is your own project. I'm driving my boosted Lude for over a year and I love it very much:-)!!Tinustussengas will retune my car in about two weeks with my new manifold and turbo..

 

my project is a bit on hold atm... lots of ppl wanting stuff made... but getting there...
tinus owns... tell him a said hi

 

The welds are hard to see....but you asked for it....lol.

I'll lead off with the good...haha. The good side, is your fitment looks pretty good. It appears to be assembled with little to no misalignment, but I'm only going on one distance shot. Overall, from the outside, in terms of build quality, it looks pretty good.

It also appears that you took some time to clean the pipe itself, so that's a plus.

Now the bad.... The bad is basically....all the welds. Between the inconsistency, some visible undercut, poor gas coverage, contaminated tungsten, and other issues...the welds are just not very good. Like I said, you posted a distance shot, so it's hard to tell. About the only descent weld quality seems to be heat control because you have fairly consistent haz's. I would suspect that it's gonna crack fairly soon in its life, just due to the weakness that is probably apparent in those welds.

Work on your welding.

 

this is indeed what i asked for

it's all a learning game... i'll see if i can get some close-ups...

 

tell me what i'm doing wrong

 

Are you pedal pumping by chance?

It just looks like contamination/poor gas coverage, mixed with inconsistent fill and movement.

Any inside shots?

 

nope... no pedal for me...

so i need to work on my steady hand?

i cleaned all the welds between the first and second pass... where could the contamination come from?
maybe the cup isnt good for this? could that be the reason for the bad gas coverage?

thnx for the help so far

 

maybe turn up the heat.

some of the passes it looks like to much filler

 

need more heat and maybe a hair more filler rod.

 

What was your gas set at? I would have to agree with more heat as well, but the temp control looks very consistent.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by AssItch1 &raquo;</TD></TR><TR><TD CLASS="quote">nope... no pedal for me...

so i need to work on my steady hand?
</TD></TR></TABLE>

No pedal at all? That definitely leaves you with limited flexibility. Also, a gas lense is very good for stainless.

What was your gas flow set at when welding, and how many seconds of post purge were you using?

 

With the amperage you are running, are you going real slow at all? I'm a little bit concerned about drop through.

 

Just more practice, it's not horrible, I wouldn't worry about the thing falling apart. More heat, a little more gas and probably a little larger filler, otherwise your fine. But those flanges look like crap... Kinda looks like a dog chewed them out of plate?

 

you might want to weld in about 1 in sections, this will help with heat soak and the welds turning that grey/blackish color. also more heat and you might want to invest into a remote, weather its a pedal or a torch adapted one. Also gas lenses work wonders on shielding coverage.

 

wow... good advice everyone...

i'll try to answer some questions...
i think i have a gas lens lying around here... i'll practice with that... but the cup is a lot wider... so it will be harder to get in those tight places....

i dont have a pedal... but after reading this i think i'll invest in one... what exactly do you do with the pedal?... vary amperage or something?

it was set at 5 seconds post flow...
and i thought the welding machine automatically set the gas flow... or do i have to set it at the... thingy... how do you call it in english... this thing:

that was set at 8 liters a minute...

the guy i made it for got the flange... not the most beautiful piece... but it works

thnx all for the advice... more is always welcom

 

Well, the problems have shown themselves. The post purge isn't long enough, you need a gas lense, you need a pedal for better heat control, and you need to set your gas flow properly.

 

what? you dont have a pedal?? i cant imagine myself welding without one. its nice that you made your own header, but the welding coukld use a little more work, but decent enough. Liek others mentioned, its heat control and your inconsistent with torch/filler movement, looks liek on some places you should have more heat. None the less, good job, you cna only improve with practice!

 

thnx... this is really helpful...

gonna look into a pedal for sure... see if i can fit one to my welder....