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Old 06-16-2012, 11:47 PM   #81
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Originally Posted by elesjuan View Post


Still haven't heard back from a single place about my flange quote. Starting to get pissed here.......
I'm not surprised. Seeing as I am the sales manager of a decent sized CNC machine shop I get lots of requests for things like this from individuals. They rarely go through, so those RFQ's go straight to the bottom of the stack after "real" work to quote.

Shops like ours are ridiculously busy right now. We are quoting 10 weeks on CNC machining which was unheard of a few years ago. Six was as far out as you could push someone the entire last decade.
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Old 06-17-2012, 03:20 AM   #82
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I'm building my own manifold. I'll be using a TD-04 WRX turbo



I made drawings and laser cut these flanges for wrx td04/5 turbos.
(If any one needs dwgs holler.)
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Old 06-17-2012, 12:25 PM   #83
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That's pretty awesome. I'm not convinced I want to use Weir-tech's turbo inlet flange. The hole in the center is the same size as the gasket, the problem is, the turbo inlet is considerably smaller than the gasket so there is a big step down. I can't decide if I want to match the size to the turbo or port the exhaust housing.
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Old 06-17-2012, 12:43 PM   #84
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I vote on port housing, but I've no experience in this.
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Old 06-20-2012, 09:51 PM   #85
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More progress... well actually progress has been pretty steady, I've just been too lazy to upload pics. But here they are.

First I fit this piece in there.




Then I made another one that is a pretty close copy but fits a little better.





Then I cut two giant holes in the first two pretty pipes I made, which I forgot to take a picture of. But it was incredibly frustrating and the last thing I wanted to do was stop and take pictures. So then I got all the pipes put back together and started the real welding today.

Autogenous root pass that I'm pretty proud of.


And another, along with a started cap pass that I'm also pretty happy with.


And I ended the day with a fair bit welded together.

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DIY manifold-dsc_0070-2.jpg   DIY manifold-dsc_0073-2.jpg   DIY manifold-dsc_0080-1.jpg   DIY manifold-dsc_0081.jpg   DIY manifold-dsc_0084.jpg  

DIY manifold-dsc_0083.jpg   DIY manifold-dsc_0089-1.jpg  
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Old 06-20-2012, 09:55 PM   #86
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very nice work so far, good job.

and I'd vote for porting the hotside. there's plenty of thickness there to smooth it out and match to flange vs using a smaller, more restrictive opening
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Old 06-20-2012, 10:06 PM   #87
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Looks like it ended up being a total bitch to make! I agree about doin a bit of grinding though. Dont want to end up cutting the exhaust gasses up too much
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Old 06-20-2012, 11:06 PM   #88
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Nice work man!!
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Old 06-21-2012, 12:00 AM   #89
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that's great work bro, soon I will do the same!
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Old 06-21-2012, 12:32 AM   #90
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that's great work bro, soon I will do the same!
Mine will look like a tattered hookers nasty vag..
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Old 06-21-2012, 12:33 AM   #91
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Mine will look like a tattered hookers nasty vag..
yo bro that one kid on this forum would be all over that!!!!
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Old 06-21-2012, 01:28 AM   #92
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yo bro that one kid on this forum would be all over that!!!!
Which one? Must be the kid wearing his sisters jeans..
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Old 06-21-2012, 01:34 AM   #93
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I don't think you understand how gross a vagina can look
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Old 06-21-2012, 01:46 AM   #94
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More progress...

Then I cut two giant holes in the first two pretty pipes I made, which I forgot to take a picture of. But it was incredibly frustrating ]
Well done Jonathan! +1

I use milling drill bits for making those "frustrating" holes.
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Old 06-21-2012, 01:49 AM   #95
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You underestimate my welding skills... lol
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Old 06-21-2012, 01:49 AM   #96
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I don't think you understand how gross a vagina can look
Pics or ban!
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Old 06-21-2012, 02:44 AM   #97
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This is America, ban from everywhere but this thread until posts pics.
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Old 06-21-2012, 03:06 AM   #98
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This is America, ban from everywhere but this thread until posts pics.
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Old 06-21-2012, 08:34 AM   #99
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Quote:
Originally Posted by baron340 View Post
Then I cut two giant holes in the first two pretty pipes I made, which I forgot to take a picture of. But it was incredibly frustrating and the last thing I wanted to do was stop and take pictures.
I hear that!

I missed this thread until now :( Very very nice job!

In the beginning I would have said that I have had bad luck with Weirtech's mild flanges, but from the pics it looks like he is back to whatever material he used to have. The last few I bought were a hot rolled? material with a bunch of slag coating each side, and on the inside of each hole from his plasma cutter, that would have to be ground off and even then still got into the welds. Major PITA. Like...4 hours to weld the pipes to the head flange instead of 40 minutes PITA. Once you get the bubblies in your weld you would have to bust out the die grinder and remove all of it, try again, etc. And that's not fun if it's on the inside of a bend between the pipe and the flange But your pics show a nice shiny almost tumbled surface finish, shouldn't be a problem.

I shipped elesjuan my last $20 crap mild head flange yesterday USPS flat rate box $11. I've shipped an entire manifold, a 90deg section of 3" pipe, and a downpipe flange in the same box for the same price, but it's the smallest box a head flange will fit in :(

My limited experience with job shops for your flange quotes...you definitely get what you pay for. I've dealt with only a half dozen or so, and quality is directly related to price. Personally, I'd rather pay the $80+ for a CNC'd flange or a quality waterjetted flange than $20 for a plasma or rusty poor surface finish WJ flange or whatever that needs XXX hours to prep.

EDIT: It looks like your weirtech head flange may need some cleaning up, I can't tell. But in this pic (I know it's not yours but shows what I"m talkign about), all the bluegreen-ish colored coating, all that ---- needs to come off where you will be welding else your welds will make your life miserable. At least that's my experience, maybe I'm doing something wrong How did your tacks go? Any splitter splatter?
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Old 06-21-2012, 11:35 AM   #100
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Originally Posted by TurboTim View Post
But in this pic (I know it's not yours but shows what I"m talkign about), all the bluegreen-ish colored coating, all that ---- needs to come off
These flanges were cut with a laser and the surface coating is typical of the process from what Ive seen. The good news with is that it is real easy to remove. I use a wire wheel to buff it clean but it can even be scratched off like a lottery card!
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