custom manifold

[Natedsmeclipse]

Looks nice. I do wonder though, will it clear your alternator? Will you have room for your downpipe?

As far as the longer pipes, I am not sure it is a good thing. The hotter the gas going in the better, right? Won't the longer pipes cool the gas more and reduce the efficiency of the turbo?

its a 420a motor the alternator is in the back of the motor. also i plan on running side exhaust. i want to get the manifold chromed when its all done and then i plan on wrapping it in spots.

well i am about 75% done all i have to do i cut the holes out for the wastgates and weld it up. i am still thinking about chroming it or ceramic coating.

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[DSM nOOb]

Just a piece of advice If you decide to ever do it again You should put a 45 degree chamfer on each piece of pipe before you tac it together. To chamfer allows for better penetration as well as your welds will come out looking more clean and flush. But it looks really good for your first attempt.

One other thing. I would look into doing an argon back up when doing the finishing welds that way your welds wont get weak and crack.

 

[99gst_racer]

Just a piece of advice If you decide to ever do it again You should put a 45 degree chamfer on each piece of pipe before you tac it together. To chamfer allows for better penetration as well as your welds will come out looking more clean and flush.

I agree with this. I do this to all of my chromoly pieces before welding them up.

But, IIRC, most sch10 pipes are pre-beveled.

 

[caboose]

You should have been welding the sections all the way around as you were assembling the manifold, from the pictures it looks like it is going to be very hard to weld in-between the pieces at all kinds of weird angles. Also there really isn't a need to chamfer the edges considering how thin the metal is, if you can weld a proper weld the bead/weld itself is going to be way stronger then the actual material you are welding on and it will look really pretty. Just make sure that your welding surface is super clean and brushed to a sheen so as not to create any inclusions and you should be good to go. IMO gas welding with mixed gas is ideal but you if you have a stainless set up with high quality flux core wire you should be good to weld the entire manifold with the flux core.

 

[Natedsmeclipse]

You should have been welding the sections all the way around as you were assembling the manifold, from the pictures it looks like it is going to be very hard to weld in-between the pieces at all kinds of weird angles. Also there really isn't a need to chamfer the edges considering how thin the metal is, if you can weld a proper weld the bead/weld itself is going to be way stronger then the actual material you are welding on and it will look really pretty. Just make sure that your welding surface is super clean and brushed to a sheen so as not to create any inclusions and you should be good to go. IMO gas welding with mixed gas is ideal but you if you have a stainless set up with high quality flux core wire you should be good to weld the entire manifold with the flux core.

schudle 40 is being used in this manifold so its pretty thick . i tacked it together because i wanted to make sure it was going to fit before i made some good welds. i am going to cut the tacks off at the flanges for each tube then make good welds then weld at the flanges. i will be posting more pics in the next few days.

 

[jnbracing]

Is that motor actually inside your house? Where are you doing the welding, living room?

 

[abaum565]

what is your mig setup right now? What wire are you using and/or shielding gas? I'm looking at doing the same thing for my holset, just need to get my mig setup right. Thanks.

Looks great btw.

 

[Natedsmeclipse]

Is that motor actually inside your house? Where are you doing the welding, living room?

yes it is in the dining room my g/f hates it but oh well she will get over it and for the welding i am welding it in my garage. take a look at my video from last year when my timing belt broke and i rebuilt it in the dining room.

YouTube - natedsmeclipse's Channel

 

[DSM nOOb]

You should have been welding the sections all the way around as you were assembling the manifold, from the pictures it looks like it is going to be very hard to weld in-between the pieces at all kinds of weird angles. Also there really isn't a need to chamfer the edges considering how thin the metal is, if you can weld a proper weld the bead/weld itself is going to be way stronger then the actual material you are welding on and it will look really pretty. Just make sure that your welding surface is super clean and brushed to a sheen so as not to create any inclusions and you should be good to go. IMO gas welding with mixed gas is ideal but you if you have a stainless set up with high quality flux core wire you should be good to weld the entire manifold with the flux core.

Ok first. You can not weld it all together while you are putting it together. When making a manifold you might end up tacking one runner in 8 diff ways to make it fit they way you want it to. Once you have the mani tacked up completely you break the runners off then weld them individually then you weld them to the flange and the collector.
Also I would like to see some pics of your welding where you are getting full penetration without chamfering the pipes and still maintaining a uniform bead without burning thru.
Also I will say if you use flux core to weld up a turbo manifold it will crack. I guarantee it.

 

[#40Fan]

I have watched your videos on Youtube before. Don't tell me you blew the motor again?

I do like the look of your header, though.

 

[tkelly27]

Don't forget about the starter too.

 

[Natedsmeclipse]

I have watched your videos on Youtube before. Don't tell me you blew the motor again?

I do like the look of your header, though.

well after i built it the first time i broke a timing belt the then i was good all summer until i broke a bolt that holds a timing baring so a hit every valve in to a piston for the 2nd time.

Ok first. You can not weld it all together while you are putting it together. When making a manifold you might end up tacking one runner in 8 diff ways to make it fit they way you want it to. Once you have the mani tacked up completely you break the runners off then weld them individually then you weld them to the flange and the collector.
Also I would like to see some pics of your welding where you are getting full penetration without chamfering the pipes and still maintaining a uniform bead without burning thru.
Also I will say if you use flux core to weld up a turbo manifold it will crack. I guarantee it.

what kind of gas and wire would you use?

 

[#40Fan]

Did I see a video of yours that you had an IC piping come off and sucked some water in?

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[Natedsmeclipse]

Did I see a video of yours that you had an IC piping come off and sucked some water in?

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nope i was working late one night and it was rain cats on dogs. so i was on my way home and i went threw this one part of town that was flooded well it didn't look bad until the water started coming up to the bottom of my head lights. well that's when things got bad my filter was just below my lights at that time and so yea i suck up so much water that it hydro locked my motor and broke a rod at 2,000 RPMs that's what happened

hey what do you guys think of hi temp paint. i read before on a posting that some people were using barb Q paint and it was holding up good. what do you guys think?

 

[Jungy]

Sorry to tell ya but I don't think its gunna clear the starter....

 

[#40Fan]

I don't know about the Bar B Q paint, but as long it is ultra high temp 1500+, it might work. Make sure any grease or oil is removed from the metal before applying.

The starter sits behind the coolant pipe that comes off of the water pump, and the header is in front of it, so it should fit in there. Getting it in and out without removing the header might be a problem.

 

[endeffect0]

nope i was working late one night and it was rain cats on dogs. so i was on my way home and i went threw this one part of town that was flooded well it didn't look bad until the water started coming up to the bottom of my head lights. well that's when things got bad my filter was just below my lights at that time and so yea i suck up so much water that it hydro locked my motor and broke a rod at 2,000 RPMs that's what happened

hey what do you guys think of hi temp paint. i read before on a posting that some people were using barb Q paint and it was holding up good. what do you guys think?

I had a ton of water in my intercooler once too. I had the UICP off because i was fabricating a new one. the car sat in the drive way for about a week of ran and the stock side mount intercooler filled up. when i went to start it up after putting on the new UICP the car sounded like it was guggleing. i put it up on stands and and it overfilled my big oil pan with water porring out.

thank god i didn't hydro lock it.

 

[Natedsmeclipse]

Sorry to tell ya but I don't think its gunna clear the starter....

i will bolt the starter up then the manifold and take a pic for you

 

[DSM nOOb]

what kind of gas and wire would you use?

I would recommend using a tig but either way argon gas with stainless rod.

 

[Natedsmeclipse]

when you put the motor in the car is the manifold and turbo going to clear the radiator??

hey think you could do me a favor see how far it is from the head to the radiator do not include the fans because i run slim fans on the front not the back like a stock 420a. and then measure from the bottom of the block to the radiator. i need to know this because i want to make sure i have room for my wastgates. thanks man or to anybody that can get me these measurements.

 

[Natedsmeclipse]

well i worked on my manifold some more i would say i am 80% about done i still have to cut hole for the wast gates but there is one problem finding room for two i am limited because i don't want to hit my radiator. but i was thinking screw it and put a Honda radiator in to make more room. my plans are to have it chromed and then wrap it with black header wrap. i think it will look good i am also going to have the exhaust housing on the turbo coated.

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[Natedsmeclipse]

hey guys i just got done putting the wastgates on and it looks pretty good i think. i do believe that it sticks out to far and will hit the radiator but i am going to use a Honda civic radiator in place it is half the size. i am going to ceramic coat it with silver and wrap about 70% of the manifold with black header wrap.

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[endeffect0]

very cool dude... its impressive what you can do with a cheap mig and some determination.

cant wait to see it in the car.

 

[Natedsmeclipse]

very cool dude... its impressive what you can do with a cheap mig and some determination.

cant wait to see it in the car.

yea i think i have like 20hr in to it so far and 16 90% elbow and 3 1/2 ft of piping you come out with a top mount manifold

 

[endeffect0]

I just spent about 2 hrs stitch welding the back half of my car. the little 90$ 120v flux core i have is such junk it isnt funny. it worked well for exhaust repair and IC pipes, which is what i got it for... but trying to do anything involving thin sheet metal is a complete fail. mostly because i have a high and low setting for voltage, and that it... Im sure the fact i suck at welding didnt help..
but hey, despite it looking like shit it will be a little stiffer in the corners, not complaints there. like you said, with a little time and elbow grease we will all go fast on the cheap.