Homemade External on 02 how to. PICS

[93jdmlaser]

I picked up my fp green and its setup for an external on the o2 housing. Well after buying a turbo like that I was poor and couldnt afford to buy another o2 housing. I started by cutting the dump tube off my internal and making it near flat with the 02 flange. Then you get a 1.5 in pipe and bump up the end a little and that will about fit in the hole. You only need like a 3in piece if that. You want to position the pipe so it sits up and towards the radiator some. I did this buy cutting it in this shape

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You get the idea. Im no artist. The pics show how to place it once its cut like that. My first time with the mig welder so its not that great and its the gasless stuff but it got the job done and saved me money. Any questions let me know or you need another angle let me know. Ill get some pics when it goes on the car.

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[Stapl3]

That will crack in no time.

 

[93jdmlaser]

Yea that helped. Anyone out there want to give me some advice on what to do and not just say it wont work. I was gonna weld a brace to help hold it.

 

[Stapl3]

The welds are on top of the two parts, they are not sucked into the two parts. Sure, it's holding together, but the two pieces are not fused together. Just globbed.

My post was to discourage you from using it. You'd just be wasting your time as it will crack.

Best of luck.

 

[awdrst]

I would suggest practice welding as much as you can. I learned on alot of flat steel i had laying around to get the feel for it. I found that it was alot harder to weld round tube when i first started especially when you are going from such a thin piece of tube to the thick flange. It took a while to get the feel for putting most of the heat onto the flange and melting into the round pipe. The wastegate tube looks like it will crack soon with the weight of a wastegate on it. You can always practice on junk metal than cut off the tubes and always grind down the flange and reweld it. Do you have any pics of the inside of the flange where it meets the tube? Another good thing to do is join some welding forums they are full of great info and are more than willing to offer up advice.

 

[BrokenTsi]

Youd be suprised with whatll hold em. Ive built countless o2 housings with a simple 80$ HF welder, and they hold up to the most aweful beatings. O2's really dont have THAT MUCH stress on them if you have a solid exhaust that isnt flapping around.

 

[Coup D E'Tat]

Youd be suprised with whatll hold em. Ive built countless o2 housings with a simple 80$ HF welder, and they hold up to the most aweful beatings. O2's really dont have THAT MUCH stress on them if you have a solid exhaust that isnt flapping around.

x2

My first MIG welds were embarassing, and they're still going strong.

 

[93jdmlaser]

Yea I talked to the JM Fabrication in Philly and he said it should hold cause mild steel wont expand and all that stuff that causes cracking. Any other opinons. I know the welding is that good but when your poor you just want it to work. Thanks guys

 

[Stapl3]

Mild steel expands

 

[TimG]

Maybe make a bracket to weld your to your downpipe so you can bolt it to your block. this should eliminate any unwanted weight on the welds. It should keep it alive for longer.

 

[BrokenTsi]

Those brackets to the block i really hate. And that more than likely with a poor weld will easily snap off. Mild steel actually expands almost twice as much as stainless steel. But using ALL mild steel parts, flanges etc will help because everything will be at the same expansion rate. Its when using SS tubing, and mild steel flanges that problems could happen.

 

[93jdmlaser]

Yea I thats what I was saying. That the ss expands differnt. Thanks. I hope it holds up for a while