Hey guys, long time no post

I would like to share with you a challenging fabrication project my crew and I just finished. All this work was done at AFI by our small team of fabricators and welders.

The customer brought us his S2000 with a Full-Race clone of the AFI T4 divided front mount manifold and downpipe. He had scheduled a dyno appointment the following week and needed custom charge pipes and since this was going to be a driver he also wanted us to fabricate dual recirculating dump tubes.

Due to the position Full-Race decided to place the twin wastegates the only logical way to have any kind of open dumptube that wasn't 3 feet long would be hood exit. Now we all know the stress dump tubes are under and how hood exit pipes aren't exactly practical for everyone. It just felt like they didn't really think that part through and our customer didn't want to deal with it.

Some of you guys know the pains of recirculating, I certainly do. Now add in a tight chassis with two of those and you can start to see how this project was a fun one (it really was). I always try to prototype and fabricate with the big picture in mind, efficiency, strength, reliability, exhaust leakage in this case, ease of installation, and last but not least aesthetics. I believe I was able to hit all these points square in the face and my crew and I are quite happy with the result.

Specs- 35r with ATP 1.06
Dual 40mm TurboSmart gates
Hypertune intake manifold
Built block
400 Hp desired

Now let the pictures tell the rest of the story
















As you can see we used 1.5 inch tubing off of the wastegates and they slipfit into a low angle collector that smoothly transitions into 2.25 and then into a very high quality braided on the inside flex section. This flex is then connected to the 3" Full-Race downpipe at a very minimal angle to minimize exhaust turbulence that might have a negative effect on turbine back pressure. I also fabricated a couple custom sized t-bolt clamps for the slip fit collector to ensure zero leakage.

Its still just a bunch of metal, but damn, you just gotta love how sometimes things just come together Cheers guys, enjoy the pix and please leave feedback if you like.

 

Damn good work guys. Looks great!

 

I think you did a VERY nice job on that, the tubes look like they are part of the manifold almost.

I personally would have just dumped them externally, sounds so much sweeter, but that wasnt what the customer wanted.

 

Th recirc wouldn't have welded as nicely without great fitment. Good job Vince.

 

What a nice dump!

 

It's nice, very nice! , but I don't like your logo. The location is my problem. Like it doesn't belong there.

 

Thanks. The fact they follow the manifold so closely (within 1/4, safe but tight) is not by accident. The customer expressed the want to heat wrap the manifold and maybe the dumptubes to keep heat manageable inside the engine bay. You have to think about how there are now six exhaust pipes within a very confined corner of the engine bay that also houses the fuse box (recessed). Keeping everything close and tight should also help with the ease of later fabrication of a heat shield if needed.


Aaron the modest melter. Dewd, have you seen your fab thread?


I agree with you %100 but it comes down to opinion VS strength. We Tag our work, everyone tags their work.... There are only 4 possible choices for locating the tag due to the available size, on each side of the middle weld on the dumptubes. I would have liked to cut the bends short on the top dumptube and weld in a longer peice of straight but that would have added one overall weld joint to it. The Tag then could have been centered but would it have been worth another potential point of failure?

Thanks everyone for the comments and feedback

 

Very nice fitment..

Where did you get this small 1.5" v-bands?

 

got any s2k turbo manifolds laying around by chance?

 

wow, looks great.

 

Hey Joe! I'm really not trying to talk **** about Full Race. The point of this thread was AFI's solution to a poorly thought out manifold design. The things I have said that were negative about Full Races clone have been facts and I think everyone can agree with me on this.

As far as AFI and it's product failure goes I think your comment is a pretty low blow. I would like you to know that since the new team of fabricators and welders have taken over we have not had any failures to speak of and our quality is among the best in the industry.

My own shop, CTD Fabrication, only takes on small custom fabrication projects that do not interfere with the business of AFI. When this project came about we had the time and space to squeeze it in. I do not steal business, I believe there is plenty of projects to go around and that we can all work together. Maybe even some day the Arizona turbo scene drama will come to an end I hope. Until that day comes...all is fair in love and fabrication....competition breeds excellence.

You know I love you Joe I even acquired a clutch for my Ep3 so I am just a couple steps away from a much anticipated Locash tune

 

Thanks! The dump tube vbands came with the turbosmart 40mm waste gates. This is my second project working with TurboSmart and I can say they blow Tial out of the water.


Yes I believe we have a couple in stock on the shelves at AFI. We also make a V banded top mount and a T4 divided top mount for S2ks.

 

Amazing job on that piping! You definitely have some skills!

I'm not that familiar with the engine bay of an S2K but that seems to me like that is some really odd turbo placement by Full Race.

 

Can you send me some quotes?

 

az turbo scene: we know drama.

 

Looks great

 

that is really nice work bro i wish we had good fabricators that can do this in mass

 

Better than TV huh

But seriously Jackson, I value your opinion

 

awesome work vince

<<<<<<<<very happy CTD customer

 

Only to those in AZ. Everyone else has focused on the dumptubes. Which is important for all.

 

looks bueno! and az is where all the awesome fabricators are.


mike

 

hah!

why no v band connection instead of a slip fit? woulda been mas baller.

 

also this.

 

I assume it was to save space, since there are already 2 flex connections.
I think it looks great, and was a great way to re-circ the gases at owners request.
It does look like those slits in the expanded ends were cut with a zip disc though. Or, at an angle. A real simple 1/8" hole at the end of them would have served great as crack inhibitors.
The stresses of expansion and contraction with those slits would not be trivial. I realize it was likely done in attempt of a better seal, but they really aren't needed with good tolerances.

 

Not yet Jackson, not yet. I think the boys across the street mistake my kind silence for weakness.

You'll know if or when I'm "all in".