Custom exhaust manifold build

[BeatupVR4]

I just bought the same flanges and piping to make a manifold of my own and I really have no idea how to do it. This thread will be a life saver. Good work so far and keep it up!

 

[2gmummy]

Im thinking of trying this myself hopefully this turns out good hahaha but is this going to be standard, topmount, forward facing?...

 

[Archer Fabrications]

Im thinking of trying this myself hopefully this turns out good hahaha but is this going to be standard, topmount, forward facing?...

i think he said regular facing.
MORE PIX!

 

[SlowChild3]

I started with 3" long tube. I marked the tubes center line and cut at an angle leaving 1/2" of straight.

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I then smashed the tube in a vise to get more of an oval shape to match the flange. After I smashed it I hit it on the belt sander to get my miter joint back flat. Make sure the 2 pieces match up good.

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Measure the OD and subtract the wall to get the ID to give you a rough idea where to trim to. I messed up on my first piece trimming it in vertical. It needs to have a miter because its wider at the top. I had to trim for the miter causing my opening to be to large. That's ok, big hammers work well.

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You can see in that picture the opening is to small. The more you trim the bigger your hole will get. It takes some work in a vise to get your ends more square to match the flange. Trim together on flange to get a good separation so you can weld the joints easier.

I haven't welded it to the flange yet but im getting close. It will be welded inside and out. After welding the inside the offset from tube to flange will be blended smooth.

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[bmoha7321]

very nice

 

[Archer Fabrications]

very nice

also subscribed

 

[SlowChild3]

I welded the two collectors together and surfaced it. Then welded the collectors to the flange.
Gotta do a little polishing still.
Turbo collector done!

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[TSi Kid]

So sexy, this makes me want to learn how to weld.

 

[SlowChild3]

I've decided I'm not happy with it. Im going to beef up my welds some. I'm also gonna weld the collectors in the center. I don't want to worry about it. I assume this is going to be the hottest point in the manifold.

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Picture of the port and polish I did. Plan to smooth out a little more.

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[doubleclutch99]

Very nice sir. have you given any thought to welding a brace in between the 4 tubes before adding the runners?

 

[SlowChild3]

Very nice sir. have you given any thought to welding a brace in between the 4 tubes before adding the runners?

No but I think I will. That would be alot easier than welding that deep. Was gonna be pain. Thanks for the idea. Ill cut out a plate to fit the radiuses.

 

[doubleclutch99]

I always thought that would add some extra strength to a tubular header. i'm happy to help with ideas.

 

[imagine-02]

Very nice!
What angles did you cut the straight pieces at for the collector? Did you have to make a jig to cut it?

 

[SlowChild3]

Very nice!
What angles did you cut the straight pieces at for the collector? Did you have to make a jig to cut it?

If my math skills are any good.... 78.69*

No I just help with my hand on chop saw.

 

[turbodsm007]

beautiful work bro can wait to see the finished product ...keep it up

 

[SlowChild3]

So I got my motor back in the car along with the dipstick, radiator, and fans. Wow! I thought I'd have more room. Should I worry about anything else in the way? I was wanting to run the internal gate but I might have to change plans. My WH1C has a vertical actuator.

 

[TSi Kid]

More pictures!

 

[SlowChild3]

Has anyone relocated the water pipe to gain more room for the compressor cover? I'm thinking about routing it at the bottom of the block and under the engine mount.

 

[TSITurbo95]

Any update on this?

 

[Imback]

They sell little stars that you could possibly use if you wanted to go that route. I personally like welding it as is but everyone has there preference.

 

[SlowChild3]

No big updates. I noticed with the flanges I bought the head and turbo needed porting. Had to do this before I began. Just waiting for the temperature to come back up.

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[SlowChild3]

I did this in 2 hours. Gonna finish trimming and then cut it apart to weld in sections. Ill give more description when im done.

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[Gamble97]

I like it, and I would like to know how in the world you are going to get into those tight spaces

Do you weld the whole thing up at once or do you do say one runner at a time then put it on the jig then do another runner and put that on the jig and so on?

 

[SlowChild3]

I've looked at it for an hour. Doesn't matter how I do it. Its still gonna be a pain in the ass. Lol
I'll weld the tight spots with a long bent tungsten in a purge box.

 

[jcarmichael]

this is amazing, wish I had the skill, or patience to learn this skill. good luck subscribing.