Custom tubular manifold project

[MarsaGSX]

hey ..next pics of my project

we taked out last 4elbows with center with turbo flange...because of big problem with LAST WELD
next how looks inside of center section/turbo flange inlet.
And welds inside of tubes

 

[MarsaGSX]

this is FINALL look
All I need to do is Tap EGT gauge

check up for
my uncle threw welding
we welded inside of turbo flange to strong/prevent crack
then Ported
same stronger-welds on "Head flange"
then ported each runners

 

[MarsaGSX]

and next pics
So what is finall result guys? Let me know

Venca

 

[MarsaGSX]

That looks GREAT Venca! Post the final results and get that beast on road!

you got it DONE what you sayin
Threw this week my friend..DSMtuners member halik008 will send LAST package from U.S to Czech (1G TB and 3" muffler ) and will finished my setup this stuf should go 10days..but wanna start my engine now! need to wait for my comp. cover-welding 90degree elbow on it to run FMIC. then install my charger with manis,tap OIl lines..and run
Venca

 

[alex99gst]

Congradulations man, that looks really nice for a DIY manifold.

 

[TurboSportAWD]

Time to polish it!

 

[DSMcrazy3]

That manifold looks bad dude! Great job on it!

 

[MarsaGSX]

Time to polish it!

Its just mild steel (which is god up to 1300Celsius...exhaust gases are around 850Celsius.)
So there isno way how to polish mild steel... Only get Chromed..
My way is Exhaust wrap
Venca

 

[goalieman24]

very nice work

reminds me of one of these guys...

 

[kicker91laser]

Hey Venca, what exactly did you use for you bends? Can you post a link? I just bought a tig welder and this looks like a fun project

 

[TurboB5]

looks great!

wiah i knew how to weld

 

[99gst_racer]

Great work, Venca. One quick question - What is the thickness (gauge) of the tubes?

 

[thekellbeast]

Hey Venca, what exactly did you use for you bends? Can you post a link? I just bought a tig welder and this looks like a fun project

He's out of country. The cheapest place for him to get bends is going to be outrageously expensive for you. There are places online to order premade SS or MS U bends, then cut them to what you need. Hell, the place I was looking at the other day let you specify the radius and all that. If only I could remember the link...

 

[95redgsx]

does anyone sell the flanges or do you have to fab those ? I to just bought a tig and am looking for a nice project to undertake

 

[MarsaGSX]

does anyone sell the flanges or do you have to fab those ? I to just bought a tig and am looking for a nice project to undertake

I made on AUTO CAD software.. on PC and my friend burned on Laser..
BTW could be very difficult made custom flanges! Don´t forget its 10mm thick wall of metal And if you wanna make SS..its maybe 2times difficult than mild steel...
Venca

 

[MarsaGSX]

very nice work

reminds me of one of these guys...

hell you right! like from miror

Venca

 

[99gst_racer]

does anyone sell the flanges or do you have to fab those ? I to just bought a tig and am looking for a nice project to undertake

http://www.roadraceengineering.com/flangesandgaskets.htm

http://www.full-race.com/catalog/pr...d=220&osCsid=ff7d3e2d278110132e2768be37e78765

 

[MarsaGSX]

Hey Venca, what exactly did you use for you bends? Can you post a link? I just bought a tig welder and this looks like a fun project

like thekellbeast wrote..Iam outta city...state...continet
but I get mine for very cheap..was like 5mins of scare..than you went threw gatehouse my buddie is really good

fun project Damn..wasn´t really funny...milion times checking..trying to match each of elbows to make BEST radius after weld..without stairs..know I mean..
next..you get heated hands.redlike Sun ..have to check tons of other issues threw building..
I said once..never ever will make again!
Venca

 

[MarsaGSX]

Great work, Venca. One quick question - What is the thickness (gauge) of the tubes?

hey Paul,
walls are 3mm thick...
befor start on this manis I was in one local fab. /Company..there are OLD WELDERS..you know these 50years old MASTERS which welding and fabricating with metal THREW their LIFE!
they told me..these elbows are okay... Faith
Venca

 

[95redgsx]

http://www.roadraceengineering.com/flangesandgaskets.htm

http://www.full-race.com/catalog/pr...d=220&osCsid=ff7d3e2d278110132e2768be37e78765

Thanks for the links , now to decide between stainless or mild steel

 

[Scott_S]

That looks awsome man...wanna make me one

 

[MarsaGSX]

finally its installed and engine run... made N/A from my awd for now.until my IC pipes will finished..my GM Maf is on TB...

But got some issues..DSMlink shoved : idle like 1100rpms (engine warm), O2 like 0,9!
A/F ratio 18:1..its on idle...
and WORST thing..my 50trim is leaking OIL into O2housing ..inside of housing..on walls is OIL! Iam boring of this..How can fix that charger..??..need to get new rebuild kit..or,I had my turbo on pieces and bearings looks not wel..but why that thing leaks? When start engine White smoke is going from exhaust..bellive its from that turbo..not threw piston rings..
Tommorow take out O2housing and check that thing..

BTW that horrible Hard work with uninstall my Tubulars..couls take 2-3hrs! ..2-3hrs with "wrecking Hands"

tommorow post some pics
Let me know..THX

Venca

 

[larsrya8]

You need to calibrate your MAF-T using the airflow sliders in DSMLink. Use the DSMLink forums to find the instructions to do this.

 

[MarsaGSX]

You need to calibrate your MAF-T using the airflow sliders in DSMLink. Use the DSMLink forums to find the instructions to do this.

checked DSMlink forum and there is lot of calibrating threads...but didin´t found
how - to
but found that if GM Maf isn´t calibrated ..it doesn´t hurt so much performance...
BTW..When start engine,my idle go to 800rpms or so and then slowly goes UP..to 1000rpms.sometimes...

next thing..my A/F ratio.
if check A/F ratio /props..can set injectors ,there is 450cc..but I got FIC 850cc..and when set mine-850 my A/F ratios goes from 18:1 to 12:1 or so... there is dead time too... which is 315 usecs for 850´s-check my log

next
when go to ECU/Airflow. there is MAF adjustments..Two dialogs..MAF settings and VE table.
in MAF settings there can choose between Fake Maf and Use MAP...and sliders
when ordered my DSMlink said will run GM MAF/Maf translator,blow threw...
my question is:
Do I need fill any of that two?I think I don´t have to since they set into my chip...???



will have to complete whole setup..make IC pipes...install my 1G TB BUT!as for IC pipes..have to wait cus only ALU welder got Tons of work..and don´t have time for me as for 1G TB..is still in U.S at my friends house..is outta city and returned around 22nd this month..then he´ll ship)

first of all.have to check my turbo Oil leak from ehaust side tommorow take out whole ..tubulars with charger...can´t sleep what´s wrong...
Thank you
Venca

 

[MarsaGSX]

check up ...
.....I got N/A AWD..but
Already Taped for EGT gauge..on 1st cylinder. read a big thread about..some people said that 2nd cylinder is Leanest..and is good tro Tap on 2nd..Taped on 1st..