What are my manifold options?

[LarryJoe]

Right now I'm running a SBR G50, SBR Tubular Manifold with a 4 bolt wastegate flange, and a Tial F41 wastegate. I love this setup and would like to keep it but I'm having an issue. My manifold starting cracking in multiple places so I had it rewelded at a local shop here. It didn't last me long at all and before I knew it, it was cracking again. I then had it welded at another shop and I got the same result. So I've decided to just find a new manifold (preferably cast) but I can't seem to find any that have a 4 bolt wastegate flange. Do any of you know where I can buy a decent one without paying a ton of money? I'd prefer it to have the wastegate flange already on there because I honestly don't trust any of the shops to weld it on around where I live.

 

[crimsondragon]

It's rare to find a manifold nowadays with a 4 bolt WG flange. From my brief search, majority are either 38mm two bolts or they stepped it up to Vband.

That G50 is a DSM turbine housing right? Is the WG hole welded? Have you thought about going to a WG on the O2? I don't want you to spend more than necessary but there aren't much options to begin with.

Here's a 4 bolt flange O2 housing for cheap.
95 99 Eclipse 2G DSM 46mm WG O2 Housing Dump Pipe 4g63 | eBay

If I'm correct that'll allow you to still use the WG, then you can choose your manifold from there.

 

[LarryJoe]

I'm not 100% percent what's up with the wastegate flapper. I've never seperated this turbo from its o2 housing since I bought the setup. There appears to be no arm for an internal wastegate. I would go with that o2 housing but that definitely doesn't look like a normal downpipe flange so it wouldn't work with mine.

 

[crimsondragon]

It wouldn't be too hard to change it. But it'll be moot if the flapper is welded which it most likely is. Can you open it up and see what we're working with? I'm curious as to how well it's welded and if it's just tacks, it should be no problem to break it loose.

 

[LarryJoe]

I'll pull it off and get some pics here in a few days when I can get that housing. Should I have a shop cut off my downpipe flange and covert it to vband?

 

[crimsondragon]

You can do either or but I think the 2 bolt flange is cheaper and it's more common.

*edit*
Take note, that outlet is 3". Most downpipes are 2.5" that open up to 3" after the flex.

 

[LarryJoe]

So how would I have them do that? Reduce the housing flange size or increase my downpipe diameter around the flange?

 

[crimsondragon]

You could have the downpipe changed from 2.5" to 3". Personally, I don't like the option and the housing being 3" doesn't work well either. Assuming the flapper can be removed, see if you can get in contact with a vendor or fabricator that welds up O2 housings like JMFab or Punishment Racing. Maybe they can customize one of their housings to have a 4 bolt flange. It might cost a bit more though. But it'll be cheaper than modifying your downpipe/O2 housing.

If that flapper is welded shut completely, you might need a custom manifold then with a 4 bolt flange. Not cheap either. Sorry but the options are really limited.