Anyone hungry for some pie?

This is a current sidework project - 2000 Civic SI with an HX35. Owner wants to retain A/C compressor (Florida) so the downpipe is tight. A standard radius 2.5" 90 would not work, so I made a handful of 15 degree pie cuts and was able to squeeze it in there, as well as clocking it so that all 5 bolts could be removed with ease.

Owner also wants to keep factory exhaust (sleeper maybe?) so I cut the ball/socket flange from OEM downpipe to find it sleeved and packed with sound deadener. OD of the factory cut piece is 2.125" - so I will have to take a 2.5" x 2" concentric reducer and cut it back slightly so that I can buttweld it to the OEM cutoff piece. O2 bung is retained in the factory location just before the ball/socket flange.

Anyway, specs on equipment used:

Miller Dynasty 280DX
CK 300 amp 2 series water cooled torch, gas lens, #7 cup, 2% thoriated (3/32")
1/16" 316L filler rod where needed
Jet HVBS-56M band saw for miter cuts

 

Looks like a tight squeeze! Compared to this, my downpipe was a breeze.

 

I'll be honest, I hate pie cuts with a passion, but this is the best pie cut utilization I've seen. And it looks like there really wasn't any other option.

 

Thanks, I really am not a fan of them either, but from the holset flange bolted to the turbo, I had just a bit over 3" to the A/C compressor.

So it required a bend with a centerline radius of 1.75" (using 2.5" tube) and you cannot get there in a mandrel bend.

 

Finishing off the project...

 

Soooooo, how are ya gonna put a filter/intake on that turbo with the dump tube right there? Or is there more room than the picture shows?

 

That was my question too, to the owner. The turbo mounted angle puts the compressor housing angled to the radiator, and with a puller fan, there is not any room for a silicone coupler/elbow. I suggested a pusher fan, however the owner is planning on running a mesh screen & clamp setup from what I understood.

 

Did you weld both the inside and outside of the DP?

 

It was a full penetration weld with back purge.

 

Nice work, but that compressor is going to die, No?

 

So he wants the "performance" of no filter, but AC and OE exhaust.......

 

How much would you charge me to build one of those with a 3in v-band? I don't have a/c anymore, but I need a good downpipe.

 

I tried to reply to your PM, but you have too many messages and your box is full.

Empty your box out.

 

There were only 2 messages in it...I deleted them, so it should work now

 

Favorite part about this post is the tubing clamp. Need me one of those!

The work you did looks great. Your customer's tastes, however, are highly questionable.

 

My fav part is that huge turbo and all that back pressure

Even with no gate he wont make more than 8 psi

 

 

Someone hasn't done his research before posting. I know people who have ran 30 psi with a hx35 on a b16. And I'm currently running 12 no problem. Going to bump it up once I build the motor a little more. They take a little while to spool, but they work good.

 

Are you on the factory exhaust?

Because the car in the OP is.

 

Hell of a job mate, looks great.

 

I give that AC compressor 2 months, tops

 

hey man very nice work. i'm a begginer welder doing some similar stuff and looking for tips.
what do you use to clean the tubes after welding to give that shiny look without ruining whe scales of the weld?

also, how many amps where you using and what gas flow on the purge to get that nice root? what is the wall thickness of the tubes? i'm assuming its a schedule 5, about 2mm?
check out some of my pie cuts. sadly right now I only have 1 gas regulator so no purge for me ;(

 

'scotchbrite blue' is what I use at work to remove any discoloration without marring the weld.