antilag_200
20+ Year Contributor
- 226
- 33
- Oct 28, 2002
-
lansing,
Michigan
This is a header attempt for my awd colt, I am building it, in an attempt to increase my fabrication abilities and TIG welding. I am a novice TIG welder, and am learning some of the key points of fabrication
So here we go
I am building a small fixture so that I can work on it , without a car present
and without the stock manifold in place: A pretty simple start.
all the accessories for my first tubular manifold for the colt... merge collector, flanges, weld els, tubing etc etc
a shot of the collector
and my son and I figuring out how to put this puzzle together
and a couple of shots of the colt in this frigid time of the year
Tubular Header Fabrication Attempt
Key notes :
1) Stainless flanges
2) 1.5" Tubing
3)Runner length 28 inch
4) Stock dsm turbo locations
5) Head flange to radiator 9 inches
6) flange to timing belt 3 inches
7) height limit 6 inches from top of flange
8- No provision for dipstick ( will be removed)
One of the challenging things for me in regards to this manifold, is the proximity of the turbine inlet to exhaust port of runner number 3. With that being said , I had to get creative with the location of collector in regards to that specific runner. Inorder to try and accomplish this, I had to pie cut the entry to the turbine housing, as the picture below illustrates. Keep in mind that I was also trying to ensure that I can get to the bolts and nuts to attach the manifold to the turbo , as well as the cylinder head.
Once I had this portion oriented how I wanted, I began to construct Runner #4 as it would be the longest one in the manifold, and where I need to get a given length. A shot showing the collector , runner number 4 complete, and the start of runner number 3
here is front shot, showing how far down runner 4 goes down, also I hope I have enough clearance for the wastegate that is off the turbine housing.
top view
side view
Runner 1 and 2 are going to "side wind " past the timing belt area inorder to attain that 28 inch runner length
Finished up runner #3 , I like the way it turned out.. I basically tried to make it follow the path of runner #4 , while trying to attain 28 inches of length
Next I planned my attack on #2 and number #, these are just the start of them, so they are not completed yet
a view from the rear, looks like a convoluted mess..
and now some over all shots to kind of show you what it looks like as a whole
this is alot of fun.. I won't be making another one again.. it is quite labor intensive. But I suppose everyone needs a hobby,
Critique, Laugh, re-engineer, enjoy etc
more to come on this project
warren
So here we go
I am building a small fixture so that I can work on it , without a car present
You must be logged in to view this image or video.
and without the stock manifold in place: A pretty simple start.
You must be logged in to view this image or video.
all the accessories for my first tubular manifold for the colt... merge collector, flanges, weld els, tubing etc etc
a shot of the collector
You must be logged in to view this image or video.
and my son and I figuring out how to put this puzzle together
You must be logged in to view this image or video.
and a couple of shots of the colt in this frigid time of the year
You must be logged in to view this image or video.
You must be logged in to view this image or video.
Tubular Header Fabrication Attempt
Key notes :
1) Stainless flanges
2) 1.5" Tubing
3)Runner length 28 inch
4) Stock dsm turbo locations
5) Head flange to radiator 9 inches
6) flange to timing belt 3 inches
7) height limit 6 inches from top of flange
8- No provision for dipstick ( will be removed)
One of the challenging things for me in regards to this manifold, is the proximity of the turbine inlet to exhaust port of runner number 3. With that being said , I had to get creative with the location of collector in regards to that specific runner. Inorder to try and accomplish this, I had to pie cut the entry to the turbine housing, as the picture below illustrates. Keep in mind that I was also trying to ensure that I can get to the bolts and nuts to attach the manifold to the turbo , as well as the cylinder head.
You must be logged in to view this image or video.
Once I had this portion oriented how I wanted, I began to construct Runner #4 as it would be the longest one in the manifold, and where I need to get a given length. A shot showing the collector , runner number 4 complete, and the start of runner number 3
You must be logged in to view this image or video.
here is front shot, showing how far down runner 4 goes down, also I hope I have enough clearance for the wastegate that is off the turbine housing.
You must be logged in to view this image or video.
top view
You must be logged in to view this image or video.
side view
You must be logged in to view this image or video.
Runner 1 and 2 are going to "side wind " past the timing belt area inorder to attain that 28 inch runner length
Finished up runner #3 , I like the way it turned out.. I basically tried to make it follow the path of runner #4 , while trying to attain 28 inches of length
You must be logged in to view this image or video.
Next I planned my attack on #2 and number #, these are just the start of them, so they are not completed yet
You must be logged in to view this image or video.
a view from the rear, looks like a convoluted mess..
You must be logged in to view this image or video.
and now some over all shots to kind of show you what it looks like as a whole
You must be logged in to view this image or video.
You must be logged in to view this image or video.
this is alot of fun.. I won't be making another one again.. it is quite labor intensive. But I suppose everyone needs a hobby,
Critique, Laugh, re-engineer, enjoy etc
more to come on this project
warren