Heres some recent fab, just got a digital camera so I can post pictures of my work, let me know what you would like to see more of my time is split pretty evenly between racecars/trucks and sanitary process piping.

Downpipe for mk2-3 1.6 or 1.9TD's, 3"ss:


With V band flange:


Compared to stock downpipe:


Top view installed, brake line and coolant line clearance, it is a bit close to the brake line, lots of room on the coolant line.


Shift linkage clearance at max throw on the o2o transmissions:


Steering rack clearance, fits 1.9 (tall block) or 1.6 (short block). 1.6 block used here.


3rd Gen common rail cummins manifold. T4 split turbine, paired primaries equal length within 1/8"Making a few more of these for a team racing the baja 1000 this november:






Sanitary weld on process piping for a milk plant, notice the interior consistency, the outside looks a bit funny because it was polished. Usually this is too much HAZ area for the interior for process piping but this particular line was for crude cheese product so I turned the purge down to save them some money.




Some manifolds for rallyVW, they won their class with their 2 dr TDI race car at Pikes peak with these manifolds.

 

looks good.do you make honda manifolds also?

 

Haven't made a honda manifold in a long time, I don't really do much honda work, mostly vw, audi, bmw etc not that I am apposed to it, just haven't had many honda guys drop in.

 

nice work , how much power do those baja trucks make?

 

Alot of nice work there. How did you get involved with Baja teams?

 

How's the Cummins react w/ a long runner manifold? What are they spinning them to?

 

in for details on the cummin's manifold

 

Very slick looking root on the inside of that piece of process pipe! I didn't even notice the HAZ was large. Do you ever have to walk-the-cup on any of that process pipe?

 

I'm not sure how much power the baja trucks are making, I'll know in a few weeks once they get on the dyno and I can tune them. I think they are shooting foir around 500whp at around 1000degrees egt's. Power figures are low because the race is about 60-70 hrs and its more about driver skill and being careful than mass power and speed. I don't know exactly how the manifolds will work on the trucks yet, I don't think there will be a major power increase as much there will be a massive drop in egts and emp's. Again I'll find out in a couple weeks, I'll post up my results. I got involved on the baja stuff through a buddy of mine that is doing the headporting on the trucks.

On the process piping I never walk the cup, only one time while working at coca-cola they had a welding **** from the states fly up here to check my welds, he insisted that I walk the cup, so I did for two welds, he left the room and I never have again.

I'd also like to point out that the weld on that process pipe was done without a positioner/rotary table, high freq start, foot peddle/finger control. Old school scratch start at 50amps and the consistancy is all in the hand

 

So here is some on site sanitary fab, this is a gear belt cover for a conveyor in a fragrance and lotion factory, 304ss, .065 sheet, cut it out with a 5" angle grinder with a .040" cut off disk, than cut a 3" band to mate, welded with a ghetto old tig, scratch start, no pedal or finger control, set the amps and go! Turned out nice though for ghetto tools.
Tacked up.



Where the band meets up, it all actually came out quite good for angle grinder cutting, steady hands and practice... Didn't focus on making great welds here, they have to get polished out anyways.


Polished up:




A stand for a scale in the same factory.



This is what happens when you tig galvanized to SS, not my choice, those were the casters provided, killed a gas lense!


Milk factory hangers for some process piping I will do next week.


Milk tank I need to repair for the same milk place next week, heres proof that 316 SS can rot:




Than back to the shop to build a mezzanine for a candy factory, MS cause it will be in the warehouse, not the production area.



Heres some of the mig welds, millermatic 251, I haven't mig welded in over 6 months, using pure argon here because we haven't used mig for a long time so no 75/25 around the shop. Made welding a bit more interesting.







My CNC mill is busted right now (damn dynapath peripheral board), so over to my good friends cnc shop to work more on the t3/t4 adapter we've been drawing up. Butter smooth transition.



And thats just the first half of the day, now leavin town for more cummins work!

 

Milk bottles and cummins manifolds....your into some crazy stuff....

 

I try to keep a pretty good mix of fab, I like working in the fabrication and welding industry outside the auto industry because the quality and engineering standards are generally much higher, plus you see all sorts of different stuff, especially going mobile, different fittings, material, machines, etc. Really helps make the automotive stuff even better.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by dave@passenger &raquo;</TD></TR><TR><TD CLASS="quote">
On the process piping I never walk the cup, only one time while working at coca-cola they had a welding **** from the states fly up here to check my welds, he insisted that I walk the cup, so I did for two welds, he left the room and I never have again.

I'd also like to point out that the weld on that process pipe was done without a positioner/rotary table, high freq start, foot peddle/finger control. Old school scratch start at 50amps and the consistancy is all in the hand </TD></TR></TABLE>

Hehe, scratch starting can be so frustating when you're TIG welding. Very nice beads for and props for not using any remote amp control. I had an old pipeline welder for a teacher who made me walk-the-cup on everything, almost drove me crazy but I'm glad a got decent at it. Not as useful for auto fab though. I've just now started TIG welding again and I've been trying to get my freehanding down. I'll try to get up some pics soon. Keep up the good work.

 

u dont happen to work for I&J metal do you?

 

No I don't think I have ever heard of I&J, are those the guys down off Sumas way? I have my own shop and work as a contractor for certain jobs here and there.

I don't like walking the cup, the weld is just too wide and your HAZ area gets too big too, its just putting a lot of unecessary heat in areas you don't need it. In my opinion the whole purpose of tig is to focus the arc and heat in as small of an area as you can.

 

yeah they are...

they do alot of sanitary stuff for me..

 

Where did you get that V-band coupler? It looks a lot better than the t-bolt type ones I use on my v-bands. (Which rusted shut)

 

They are sanitary tri clamps, I like them better than normal V bands as well, tool free. You do need to make your own gasket from 1/8" filler rod though.

 

yeah i have no idea why the expletive the drag guys use those stupid wiggins clamps..

tri clamps with teflon gaskets will hold up to any heat, and will hold over 300psi.. (had tri clamps up to 320 psi)

 

Hmm that's neat. With those only being hand tightened they hold up with no issues?

 

sanitary piping is gravy stuff, I do alot of the same things that you get into for Nestle R n D in ohio, but the manifold you made not that has some time and patience into it nice work man

 

nice work

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by DESTROYER &raquo;</TD></TR><TR><TD CLASS="quote">Hmm that's neat. With those only being hand tightened they hold up with no issues?</TD></TR></TABLE>


for heavy vibration i would tighten em down hard with a wrench. they aint coming off then.

 

Sketchy Dave the works looks great too bad the douche bags with the Cummins keep changing there minds.Watching you take a hammer to break apart one of those Cummins manis made me sad.I will get you working on more Hondas soon dont you worry

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 90dxhmt &raquo;</TD></TR><TR><TD CLASS="quote">Sketchy Dave the works looks great too bad the douche bags with the Cummins keep changing there minds.Watching you take a hammer to break apart one of those Cummins manis made me sad.I will get you working on more Hondas soon dont you worry </TD></TR></TABLE>

Which one of you dualing banjos is this? Are you guys coming down this weekend?

Yeah so I had to build a new cummins manifold AGAIN, so #3 was the charm here it is installed and at the show:

The truck:


Prime piece of real estate:



The shock tower from hell that made this whole thing difficult:


Sweet billet Weld racing wheel:


Downpipe, 4" .083" wall or something like that:


And the manifold: