first fab'ed 3.5 o2 housing

[d j]

the next one i build, it'll have to be tig'ed; this one is soo ugly ;]

 

[v8s_are_slow]

Looks good enough to me. Just my opinion though.

 

[awdrst]

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.t.

If you have a metal cutting bandsaw i'd say it's a cleaner machine for the job. I use a bandsaw on all of my cuts for my exhaust manifolds. It doesn't leave the nasty burrs that the chop saw leaves that needs to be cleaned out. I will say that the chop saw is quicker but makes a little more work in the end with cleanup and all.

BTW I've seen welds that look alot worse than those. All that really matters is that it works and you got decent penetration. Another quick tip if you can find some nice 3.5 inch donuts they can make that bend without making any welded cuts.

 

[clipsit]

the next one i build, it'll have to be tig'ed; this one is soo ugly ;]

Hey I will take it and just stare at it all day in my room...it's not that ugly... Good work dj, sounds like that 4G is going to be a beast when you're done...! And true about not worth charging $300+ for a piece like that, but you could...

 

[92eagleTSI]

Looks alot better than the 3" i made for my small16 I did mine with 15* cuts and an outdated cheap mig, welds were horrible but thats what exhaust wrap is for. You say thats your first time welding!? Looks pretty good.

 

[DSM90AWD]

Very nice! I've built two complex FMIC piping sets with mandrel bends and a $7 10" abrasive blade for my Craftsman Mitre saw . My neighbor runs a HVAC fabrication shop so metal/welding is covered. It's nice to actually DIY and "have it your way" and not get some universal fitting piece that you have to "make fit".

So what are your plans for the outlet? Downpipe or plumb it out to the side?

 

[d j]

So what are your plans for the outlet? Downpipe or plumb it out to the side?

well thanks for the comments! my plans are oval tubing ran to with a 3.5" muffler or just dump it out & under the rear pass-door (oval tubing of course).

 

[jazzyjay]

I am inspired by your work and now plan on doing the same for my new turbo. How wide is the pie cut, I have it marked. With that number I could figure out the angle for a 3 inch pipe.

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[project_tsi]

Setup looks great. Uber exhaust flow for you!

 

[d j]

I am inspired by your work and now plan on doing the same for my new turbo. How wide is the pie cut, I have it marked. With that number I could figure out the angle for a 3 inch pipe.

Hell Yeah! Thanks for the comments, I had no idea anyone would give two squirts of piss about this;

The only thing i did was made two different cuts. the "half pie" you see welded to the vband-flange... well thats the inital five-degree cut. the rest are ten-degrees'.

what made this radius so tight was the thickness of the pie-cuts. if you noticed the first post (with the ghetto tape-dry fit), those are real wide (at the narrow/skinny end) cuts. what you'd want to play with is the thickness of the cuts. i made mine as close as i could get wthout ruining the narrow/skinny end. the reason for that is i needed that tight bend.

i suppose you could mesure the wide end (around 20mm's) and mark your pipe before cutting... i was in a rush to prove something to myself, so i honestly couldn't say other than guessing.

roughly, the welded-flange-cut is about 14mm, the rest should be the same 22mm +/- (in my photos) but again, i just eyeballed it and smoothed 'em out.

btw; wear some freaking eye protection.. i've been to the eye-doctor twice in 2 months to remove shit from my eye (it was hit twice). i had rust rings and all types of b/s in here. its a little scary having the doc use a eye-pick to remove rust. WTF

 

[d j]

aside: i do wish i had 'em tig'ed though.

 

[clipsit]

Uber exhaust flow for you!