Building a forward facing Turbo Manifold

[TheBoz]

VIDEO OF THE FIRST START UP.

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Galant+VR4+Forward+facing+manifold


After seeing the STM manifold I have not been able to get my mind off of how cool that would look on the Galant. So finally my brother and I, got started.


Here is the Mock up.

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Materials.

Custom One Off Head Flange - Brother CNC Machined it

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304 SS Weld El's Sch 40.
click - acestainless.com

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Here is a ghetto moch up of the pipes. We are just trying to plan everything out before we start tacking stuff together. So dont poke to much fun at the awesome blue tape .

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[debbie]

That flange is the dogs

 

[b00stedtalon2]

Badass.. I want one!

 

[TRSblader]

Looks really good so far. Can't wait to see the finished product!

 

[99gst_racer]

Kick ass flange. Should be a pretty badass manifold when it's finished.


What are your plans for filtering at the compressor? Just a screen?

 

[gixrman]

Custom One Off Head Flange - Brother CNC Machined it

That is a nice piece, you need to sell those! Not to sure I would want "prison rape" on mine though wife might not like that.

 

[TheBoz]

That is a nice piece, you need to sell those! Not to sure I would want "prison rape" on mine though wife might not like that.

, ya the Prison Rape is an inside joke between me an my brother . AMS sells a cast version of something similiar.

AMS Cast 4G63 Exhaust Head Flange - Amsperformance.com

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We are going to start tacking stuff together this weekend.

What are your plans for filtering at the compressor? Just a screen?

For now we are just going to run a screen, but later we are going to make an air box from the grill. Just stuff a pannel filter into the grill, and fiberglass a box that will connect to the turbo. So I hope that will work well enough for some basic daily driving.

 

[dsm-onster]

Do you have the radiator figured out yet? The flange is nice.

 

[TheBoz]

Do you have the radiator figured out yet? The flange is nice.

Yep, I have a civic radiator. We stuffed it in there for the basic moch up. Once we have tacked a few of the pieces together we will test the radiator again and make sure that it still fits.

 

[ApexVIII]

Do you have the radiator figured out yet? The flange is nice.

just about to ask the same thing.

is the civic radiator a half size or something?

looks really good man!

 

[95GreenGSX]

Its gunna be sick! I cant wait to see it, hope your a good tig welder. Also, I love that is on a Galant

 

[turboglenn]

That's just beautifull! I love the header flange The prison rape is going to make for some funny conversation when you're out at the show-n-shine car gather : :

Anyway, Looks very well thought out and like you're going at it the correct way. Some of those TIG welds are gonna be tight but don't just rush into welding from one angle that might need you to use too much heat before you give some thoughts to ways to add some extra shielding and get in from a cleaner angle. I've had to repair some really tight areas on some ebay headers that cracked around the turbo flanges and waste gate tube from the header to gate, and most of them would ahve been easier to take apart, fix the problem and then put them back together. Just make sure to try an assortment of cups and back caps to make sure you get the best weld as headers are picky.

Actually most of your build issues can be solved ahead of time by planning how you will put the puzzle together and what to weld into segments first before putting it together , there's a decent article on header construction on Simple Digital Systems EM-4 in the tech or pjoject area of the page and it comments on some of the things you should and shouldn't do in certain orders to make the build easier

Keep udates coming because i want to see this all come together....BTW ace is where i order mine from too. Some one tried telling me Vibrant was cheaper but from their website they are way ver priced the last time i checked

 

[awdrst]

Head flange is great. Sch40 is some pretty thick stuff. Glenn is right about the welding. I always have a huge assortment of backcaps and gas lens for the tricky parts. It's always like a big puzzle to make sure you don't get caught with a area you won't be able to get the torch into. I like to weld as much of it together when it's tacked to the head flange and collector as possible before breaking it down to keep any warping down to a minimum. I then break take each runner off the head flange and collector and do the finish welding usually only doing a little at a time on each runner. I had a few of my first attempts at putting manifolds together warp cause I would make a runner fully weld it not tacked to the flange and had to redo stuff since it didn't line up anymore. This just makes it so you can keep the warping to as little as possible. The other option is to build a jig and weld it in that this way everything stays put. One last tip is to get a old head or a piece of thick steel to bolt the head flange to this also keeps the warping down while welding. I also bolt down the turbo flange when welding the collector to it.

 

[johnboy1065]

just curious but why dont we see many 1G DSM's that are drag cars having front facing manifolds?

 

[99gst_racer]

just curious but why dont we see many 1G DSM's that are drag cars having front facing manifolds?

Probably mostly due to the fact that they require a good amount of modification to other components to make it all fit and function. There's been a handful of them made for DSM cars in the past, but there's just not enough demand for anyone to mass produce a design.

 

[garage16]

I also built one but you gotta THINK hard before doing one.

Here are some tips that may be good before you start welding it up.

1- Make sure there is room for a downpipe from it hitting the block
2- Make sure the turbo is straight and not sitting on a angle (1st manifold I made was not and the oil started to leak around the drain line brcause the oil flow)
3- Place Rad as a template so you know what to work around with
4- Have room for the intercooler piping
5-Place wastegate around where you wanna have it and watch for the flow as well for the WG.
6- Once wastegate is placed to where you want it, make sure there is room for a WG pipe
7-clearness for closing hood

Some of the tips I did not go by from doing first manifold and thats why I ran into problems and had to make a new one

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[TheBoz]

I just got the first video up. The manifold is complete along with the downpipe, now I just need to do the radiator and the intercooler and it will be done.

VIDEO OF THE FIRST START UP.

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Galant+VR4+Forward+facing+manifold

 

[spawn87]

wow that is one bada$$ set up... wish i could do it on my talon... but looks really great.

 

[94awdcoupe]

awesome job.. what size snail is that?

 

[habitatguy187]

awesome job.. what size snail is that?

Looks like a 14b to me.

 

[TheBoz]

awesome job.. what size snail is that?

37r

 

[WIDSM]

I also built one but you gotta THINK hard before doing one.

Here are some tips that may be good before you start welding it up.

1- Make sure there is room for a downpipe from it hitting the block
2- Make sure the turbo is straight and not sitting on a angle (1st manifold I made was not and the oil started to leak around the drain line brcause the oil flow)
3- Place Rad as a template so you know what to work around with
4- Have room for the intercooler piping
5-Place wastegate around where you wanna have it and watch for the flow as well for the WG.
6- Once wastegate is placed to where you want it, make sure there is room for a WG pipe
7-clearness for closing hood

Some of the tips I did not go by from doing first manifold and thats why I ran into problems and had to make a new one

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What kind of car is this this in? The master cylinder is on the passenger side. Mirage maybe?

And good job on the manifold it looks very good. I can see this type of thing really taking off soon.

 

[324vr4]

Amazing Build!!!!

 

[Burnett03]

Looks good, the drain return scares me though.

 

[dsm-onster]

It's always a scarry thing. . . Glad I'm not the only one who feels it.