I use a HF band saw. It is between $200-$250 and word reasonably well. If I could figure out how to properly adjust it to get perfect cuts it would be much better. But every time I do go to adjust it I just make it worse.

It is very hard to tell from the picture. 1/16" gap on that size pipe would be ideal. You may be able to get the center gap together a little by gaping the outside 2 a little more. The way the outlet saddles on this type of manifold is what saves it. Make the best weld joint the one that isn't gusseted with the outlet. You could also pull one of the Tee's out and "butter" up the end if the tee with weld metal and regrind your bevel and fit it up again.
Good Luck.

Thanks for the tips. I think I will pull them out and add some material. Before you mentioned that I really thought my only option was buying some new tees and cutting them and I didn't want to go through all that again.

Just keep everything clean. Spend the time grinding and in fit up your welds will come out much better.

I buy all my weld el's from a local plumbing shop. Call around and you can probably find them locally if you live in a decent sized area.

Luckily enough I live about 30 minutes from Ace Stainless.

In that case I would go buy 2 more tee's and start over just to be on the safe side.

Well, you guys convinced me. I'd rather do it right than do it twice. I'm going to order new tees today and pick them up on Tuesday.

Good choice. Take plenty of time and get the fit perfect with good bevels.

smart.

in this case I would not. I would bevel 75%, then run a hot setting on the welder. I could easily get full penn. Cuts down on having 10,000 wires inside the manifold too. Thats just me.

Got more parts today! I stopped by Ace to pick up the tees and had the ATP Turbo stuff waiting for me when I got home.

https://cimg2.ibsrv.net/gimg/www.mia...b8350f6f9a.jpg

It's nice to have an exhaust flange that actually fits now. It feels like it's good quality, not that I really would know. However, I'm disappointed in the oval transition. Even though ATP says to use it with their flange, it did not fit initially and required some massaging with my vice. Now it sort of squeezes into the relief. And now, thanks to the persuasion it needed to fit, the "round" 3" side is slightly ovaled. Wonderful. I don't think I'm expecting too much for an $18 part. If I did it again, I would much rather crush a 90 into an oval. It would be the same amount of work and save me a weld. Oh well... live and learn.

This is how one of my 1.6 manifolds looks before I bevel it.
Attachment 230193
Attachment 230194

Very helpful, thank you.

Today I cut and beveled the tees. I'm very pleased with how it turned out and can't wait to weld it up.

https://cimg8.ibsrv.net/gimg/www.mia...9c8109026e.jpg
https://cimg9.ibsrv.net/gimg/www.mia...54c43a91e3.jpg

Nice! Looks great, sooo much better than last time.

ladies and gentleman, this is what happens when real friends step in. You started off showing parts than looked like doo doo destination brokenville. We told you it was junk. You came back with nice parts and added skills. Keep going with new standards and this build will be a good one.

nice....be sure you clean the ID of the pipe also a 1/2" back or so from the weld. The first set was worth the money for practice.

It was a little while since I worked on the car since my last post. In the past two days, I really got to work and finished the manifold, the 5 bolt adapter, and I fabbed a small bracket for the wastegate.

https://cimg2.ibsrv.net/gimg/www.mia...1d67130414.jpg
https://cimg3.ibsrv.net/gimg/www.mia...e426e60b21.jpg
https://cimg4.ibsrv.net/gimg/www.mia...c5604e7556.jpg
https://cimg5.ibsrv.net/gimg/www.mia...c114e09461.jpg
https://cimg6.ibsrv.net/gimg/www.mia...8026136ea7.jpg
https://cimg7.ibsrv.net/gimg/www.mia...4d75ea7a26.jpg
https://cimg8.ibsrv.net/gimg/www.mia...382c092f75.jpg

My welds ARE getting better but still look shitty.

Update for today: I was a dumbass and bent the compressor wheel from moving around the housing carelessly. I think I'll end up buying a new wheel or just wait and buy a genuine 2554 or 2560. Or maybe another chinacharger. I don't know for sure yet, and I still have a while to go before I can get to a point where I would make boost.
https://cimg2.ibsrv.net/gimg/www.mia...861e14541f.jpg

I also fitted the manifold to the head after making the holes slightly bigger. I still need to do a little grinding so the nuts will all fit. I'm happy with how it looks.

https://cimg5.ibsrv.net/gimg/www.mia...d4c26ccea7.jpg

Yep lower cornet nuts are always tight on the 1.6 manifolds. I have not figured out a good solution for that yet.