Some pics of the DP and the turbo housing i polished installed

[turboglenn]

Here's some pics of the turbo housing i put the flange on and then polsihed up a bit by removing and smoothing the tabs on the housing

ALso, this is the down pipe i made that i had to cut the flange with the plasma and made an internal gate dump to the atmosphere. The only thing i'm not too proud of is the MIG welds, they are a little large and after TIG'ing for so long now, to me MIG welds just aren't pretty anymore .

I will say one thing about getting to work on this vehicle. This car is amazing! For a 1.8 liter mx-3 with hardly anything done to it except a megasquirt and gutting what wasn't needed from teh engine bay.

Before the custom DP the turbo would only spike 17 then drop to 12psi by redline (and that was all it could do no matter the boost control setting), now it will instantly hit the 17, and hold it all the way through redline and the logs show that it's still moving air and could use more boost and more fuel, but the fuel system is about maxed out so we're holding off on any further tuning as of yet. THe car is running a megasquirt and after convincing him to go e85 and reprogramming the fuel and spark tables to use it, the customer and myself are just amazed at how much more power this car picked up. It's making so much more power compared to most of these cars that it already smoked the "new clutch" which was what i can only describe as the equivelant to the ACT2100 for our cars and is basically the "standard" upgrade that no one has to replace and we smoked it within a week of bringing the pwoer levels up from e85, porting and this DP. He's putting in the new clutch this weekend and we are going back to tuning...

It was amazing how much difference was made by this custom down pipe compared to the OEM o2 housing which was damn near a square box shape that i'm surprised there's not more of them commercially available already.. So much more in fact that on his forum people are now in line to have me build 4 more of them and got 3 more flanges alone to make and ship. So now i have to get his DP off and build a jig so i can replicate them off the car for these people... The only other DP you can get for these cars is 258 bucks plus shipping and they won't sell the flange seperate.

I'm offering up the flange or complete down pipes for these people since the market is so slim on offerings, I"m just trying to figure out on the flages how the customer can weld their own DP and not warp the flange even though it's 1/2 inch steel plate. And since i machine them flat after welding or jig them up to where they can't warp, the best thing i've come up with is to add a shortpiece of pipe, say an inch or so long at each outlet so they can start welding their pipes to that instead of direct to the flange to keep them from getting too much heat from a MIG directly into the actual turbo flange and ruining it's sealing surface.


anyway, here's pics let me know what you think...the pic of the flange before it was cut is in the thread titles "Cool stuff (now with pics)

Also, I have to state before hand that the tube used for the wastegate dump was already cut and welded in about 9 places when he brought it instead of having me buy new stuff he thought we could just make the stuff he had work and we did.. Also, the piece of bent pipe that has "TG" welded onto it in MIG is a scrap of leftover from a year ago that we ended up needing at the last minute and found in my scrap container ... saved us a trip to the store and a few bucks even if it doesn't perfectly match up

 

[Calan]

Awesome work as usual

 

[chico904]

That is awesome! How much do you plan on selling them for?

 

[gsxtasy]

Looks good Glenn, looks like that flange worked out well!

 

[turboglenn]

Thanks everyone! I like having this supforum on here to display and get feedback on the stuff i make by other car guys instead of showing people on welding forums stuff that they have no idea what it even does

Chico 904, flanges will be about 50 bucks because there's a divider that seperates the turbine outlet from the wastegate outlet to make them truely seperate and not have exhast leaking from the open dump constantly

Or a whole down pipe will probably go for 175, the only competition is 258 bucks, looks pretty crappy from what i hear, and does not seperate the wasteagete to allow atmospheric dump, so the turbine and WG holes just dump into one piece of 2'' tubing, then it expands to 2.5 after teh first 90* bend from the turbo. Mine is 2.5 from the flange to the very end I don't think i'll have any issues with the price or selling them, but i know the market is very limited. I mean how many early model OEM turbo MX-3's do you see running around these days, let alone in goos shape and modified. But all this means is that my jig will be made with wood instead of steel and aluminum pieces so it will be good enough to make at least 20-30 and cost me only about 8 - 10 dollars to build instead of a good 50-75+ if i were to make it from heavy plate and all metal supports.

gsxtasy...The flange worked out way better than I even thought it would being that it was the prototype, or very first one i made with a plasma cutter. I did cut 2 practice ones before coming up with that one just to get my cut technique and travel speed down for good cuts )plus even the diredction mattters in plasma, the left side of the cut based on direction of travel will be beveled while the right side of the cut will be almost perfect 90* with a slight bit of concave at the most. It sealed up so well there were no exhaust leaks at all even before facing it when we were testing the fit of the divider we had to add to the flange I was very happy to say the least... and now with all the stuff you helped me bring home my production speed has picked up. IT makes a huge difference without having to keep running here and there when i either need a GOOD air source or lathe/mill work. SO im in the dungeon a little more often but oh well, it saves me gas money at the very least tehrefor increasing profits ever so slighly

 

[95GreenGSX]

I love your posts. Make sure to keep them coming. They are very informative and well written. All of your custom work is great to look at and learn about. It keeps the hopes up for guys (like me) that just started tiging not to long ago. Can't wait to see more.
Good job on the dp and dump, why did you mig it instead of tig? Didn't have alot of time?

 

[anteversion]

Yeah. nice job glenn!! i don't think that those mig welds are bad, they are not perfect but pretty much than acceptable!!!

 

[toofast82]

Chico 904, flanges will be about 50 bucks because there's a divider that seperates the turbine outlet from the wastegate outlet to make them truely seperate and not have exhast leaking from the open dump constantly

Or a whole down pipe will probably go for 175, the only competition is 258 bucks, looks pretty crappy from what i hear,

Awesome work, Glenn! I wish I had your fab skills

Don't be so nice, Id hit them for $225 on the whole downpipe

 

[turboglenn]

Well, as mentioned earlier in regaurds to the modifications we've made to the car via upgraded turbo that has been modified with a good open custom inlet and a custom DP with seperated and atmospheric dump of the internal wastegate that car has been making a substantial amount more power. ( I also just talked him into E85 about a month ago and he's been killing that think they're way out of his league since and that make me happy to see) Well, all the new found power has been a strain on the "stage 1 clutch" (that's the only way he knows to describe it from ordering it) And this last week at only 15psi it went up in smoke! He pulled the engine out of the car this morning after spending all night at americruise in lincoln, NE and brought it to me tonight after i had dinner and we did the final sealing of the turbo's outlet area to divide wastegate from turbine

On the prototype DP that was a slight leak from one to the other leaving you to hear the "open'ness" when the WG was closed , but only enough to be noticable when the car would fast idle on a start, and could lightly be heard under mild acceleration but at cruising and normal idle it was almost not there.

Here's some crap pics of the engine and turbo... The weld on the divider has a nasty little blob on it that i didn't care for but he was happy with the rest of the bead (as was I do to the fact that i stick weld about as often as christmass comes) and this was a cast piece that i was using the "cold weld" procedure on at 85 amps with some 99 nickel rods. I tried to get him to bring me the turbine housing alone but he said pulling the engine was easier than getting the turbo of and that when he upgraded it was still the OEM hot side due to the same reason .


HEre's the pics and what they are...
The first one is a close up of the prototype's flange which was cut freehand on my plasma when the air supply i was using couldn't keep up, the holes how ever were done with a circle jig and a good compressor...this is why the walls are so thin by some of the bolt holes (becuase i don't have steady hands half the time) Also the TIG welds aren't the ebst on this but to be honest I didn't even clean the mill scale off like i should have as i expected to build yet one more for the final one on his car, but he was so happy ht just wanted to get this one on and i just wanted to use what i had made to build a jig

The second shows the compressor that i welded the round stock to for a "clampable" inlet when it was previously a machined surface for a bolt on weird ass inlet for some other OEM application, but it was still an upgrade!

Third is the new divider and OEM turbine on OEM engine in the back of the truck it was brought in. his is welded into the turbo at his request but in production the divider will be on the flange and trimmable per application by a small amount

Fourth, The prtotype flange with the original test divider that leaked a tad cut off of it and smoothed back to a sealable surface. On the first divider attempt we had poor fit-up from having to shape it to the car and fit it with the turbo being mounted on the car and no way to get the proper view or access to properly fit one up... you just couldn't get in there so we ended up having to bend and beat and grind at it until it wouldn't block the wastegate from opening. (the first tiem it was put in the wastegate stuck open, the new ones are moved forward quite a biut now and have no chance of interfering with anything

5th... The back of the new flanges i'm making for this application ( there's only one other supplier and he wont' sell flanges alone, whole DP's only) I have a jig cet from 1/8th AL sheet that can be clamped onto the 1/2'' steel to allow for smoother edges and cuts from the plasma on the thicker material, the template still needs some smoothing as there were 2 spots that hung up pretty badcasing me some deeper cut lines to clean up... I want retail quality from the first cut damn it!!!! !

6th....Is the front of the production flange with layout markings on it for accurate placement of the future cuts and drilling.

And finally 7th Is the 1/8th AL template for cutting them smooth and consistantly, Thefront of the flange market with it's "allowable" areas for the divider marked in solver sharpie, Part of the OEM cast o2 housing i cut apart to use for exact positiong of the bolt hols on every unit by use of some center punch transfers and spray paint

The New production style divider will actually require the customer to at least have a dremel tool or file at minimum becuase it will be welded where i KNOW i can weld it, but i will leave an extra 1.5mm or so on eace side and maybe 1mm on the bottom so the customer can custom fit the divider to their application (for manufacturing tolerance changes on both my end and from the turbo supplier)

 

[Weapon-X]

I really like following your posts about the things you fabricate and come up with. You possess some pretty good skills.

Keep up the good work and don't forget to keep posting.