first fab'ed 3.5 o2 housing

[d j]

initally i needed some clearance from the aftermarket housings but couldn't find jack in 3.5" vband. in the photos, i didn't even bother to clean up the edges, dry fit with tape, etc.

perhaps if i motivate enough, i'll clean the edges and weld it together (or pay someone else).

chop saw - $90 Lowes Special
Disk - $5
3.5 SUS 5' - $30

 

[dnhieu]

MAN THATS AWSOME. now weld it up so i can see what the finished product looks like

 

[d j]

thanks for the comment!

(to me) it looks like to could be better now, my eyes. those are 15 degree cuts - i think doing 8 to 10 degree pie-cuts would look like a much smoother radius.
the one thing i wanted to keep was 1"+ of space between the o2 and alt & oil filter;

 

[project_tsi]

Who built the manifold?

 

[awdtalontsi1992]

Looks good man. Weld that baby up and give us a picture of the finished project.

 

[drivemusicnow]

Now you just need to run to Buschur and get the alt relocation... Unless you LIKE changing those ;-)

 

[d j]

i like the alt in the stock spot for now. when the exhaust dumps out in front of the tires, i'll surely move the alt to the back. i dont have any space/clearance issues anymore. i did contact david about creating the o2 housing for me but Buschur declined. Didn't have a mockup in place so he couldn't fab anything without knowing if it'd fit. FP said the same;

with complete o2 & downpipe in place, the oil filter clears 100%, lower intake pipe clears as does the alt. removing the o2 housing isn't too bad giving the 2" of space i have to work with. there is no way i could use 3.5" pipe under the car, Dr Gas will have to do.

Thanks for feedback

 

[d j]

Who built the manifold?

its an oldy.. SouthFlorida did it quite a few years back, when they had a legit "lifetime" guarantee.

 

[definitiveno]

What turbine housing is that with a 3.5 outlet?

 

[boosted_91_tsi]

Looks good man. Definitely get that thing finished up and take more pics!!

 

[d j]

What turbine housing is that with a 3.5 outlet?

an I.T.S. custom

 

[d j]

new housing @ 10 degree cuts. looks better IMO;

 

[phatTSi]

I would have to agree that the 10degree cuts look much nicer and would appear to flow a little better.

 

[GVR4592]

Yep, the new one looks much better. What are you using to make the cuts? Bandsaw?

 

[d j]

Yep, the new one looks much better. What are you using to make the cuts? Bandsaw?

just a crappy Lowes $99.00 Special "chop saw" (14") and a $5 dewalt blade.

 

[perley03]

Send that baby up to me so i can TIG it!!! Not bad for a $99 special chop saw and some free time. Looks good!

 

[d j]

Send that baby up to me so i can TIG it!!! Not bad for a $99 special chop saw and some free time. Looks good!

careful, you might actually get a few of these in the mail

this first o2 is just a test-fitment-mockup, i will probably try to use a few cuts from an already bent 90/110 pipe and try for a 3-piece bend (opposed to the several 10degree pie cuts).

 

[kicker91laser]

Looks pretty good! *Adds thet to the list of stuff I need to make with my new miller synchrowave 200 tig welder*

 

[miragetbo1997cc]

Now you just need to run to Buschur and get the alt relocation... Unless you LIKE changing those ;-)

Dang is that why my alternator doesn't last longer than 20 mins?Sorry for the highjack

 

[d j]

finally got the rest of it finished. the welds are not pretty but under exhaust wrap, who'll care? there is a "before wire brush cleanup" and after - not too shabby for my first time.

 

[v8s_are_slow]

Sheesh, I'd like to hear that thing run. I'm looking into doing the same thing for my T-67 but smaller diameter piping. Nice knowing what you used cause I've been trying to think of the best thing I could find and don't think I want a bandsaw doing the job. I think I'll have to start out with a 2.5 inch pipe and bump up to a 3 inch right after the 1st turn but still wondering the best way to do that.

 

[JayRolla]

Sweet, where you get your nice shiney new alt. Ive been going through the auto part store ones like crazy. Anyone know where to get an OEM for a good price? Or someone to rebuild them? Also anyone have a pic of the alternator relocation kit. they sell it for $180 and want to know why so expensive for a bracket?

 

[d j]

where you get your nice shiney new alt

everything on the block is brand new (down to the nuts, bolts & washers);
if it isn't new then i've mod'ed it in some way shape or forum.
but to answer the question... i bought everything OEM from JNZTuning.com;

My first 3 phone calls to Erik @ JNZ were about 45mins long, looking up part numbers for misc bolts. in fact it was so bad that i was the first to order some of these stupid parts (from them). anyhow, i can't say enough good things about the guys @ JNZ;

 

[d j]

Sheesh, I'd like to hear that thing run. I'm looking into doing the same thing for my T-67 but smaller diameter piping. Nice knowing what you used cause I've been trying to think of the best thing I could find and don't think I want a bandsaw doing the job. I think I'll have to start out with a 2.5 inch pipe and bump up to a 3 inch right after the 1st turn but still wondering the best way to do that.

i did pick up a dremel kit to clean up some welds and clean/polish other parts.
but all in all without buying the tools, i have $60 in this o2 and maybe 2 actual hours of work. just doesn't seem worth charging $300+ for does it?

 

[v8s_are_slow]

Sweet, where you get your nice shiney new alt. Ive been going through the auto part store ones like crazy. Anyone know where to get an OEM for a good price? Or someone to rebuild them? Also anyone have a pic of the alternator relocation kit. they sell it for $180 and want to know why so expensive for a bracket?

Lol, I don't EVEN know how his alternator and a relocation bracket relates to this thread. Let's keep it on track here man. But to answer your question, well, I'll send ya a pm with the info ya need. It's a thread from Dsmtalk though.