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Old 04-28-2010, 11:12 PM   #41
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now, did you have the flange mounted to the housing when you welded it? You may have warped it. check it.
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Old 04-28-2010, 11:55 PM   #42
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I never thought of that. I didn't have an issue with the N/A header I made. Worst case, I can have it machined flat. I will definitely bolt down the engine-side flange before welding.
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Old 05-17-2010, 07:47 AM   #43
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Well, I had some time to get out in the garage twice this last week, and I was able to finish the second primary on the turbo manifold (after many trials and re-cuts).

I originally started with the fourth primary, expecting that to be the longest, but, due to the turbo flange setup, three is actually the longest, at 38.5" long. I now have number two completed, within .25" of the third primary. From the turbo to the fourth port is roughly about 32", and from the first, only about 14". Number four should be relatively easy to come up with 6" extra, whereas number one is going to be a challenge. I expect to do a loop around the other three primaries at some point.

I realize the long primaries are going to cost me some spool-up time, but I am not overly concerned, as the equal-length manifold and the twin-scroll features should bring results in the higher RPM area.

http://i39.photobucket.com/albums/e1...TMPAUG/148.jpg

http://i39.photobucket.com/albums/e1...TMPAUG/149.jpg

http://i39.photobucket.com/albums/e1...TMPAUG/150.jpg
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Old 06-10-2010, 09:00 PM   #44
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I finally got an hour or so to work on my car... What little time I've had recently, I've worked on Other Dave's seven.

Today I stopped by the garage on the way home from work, and worked out the last primary. All four are now within a quarter inch of 38.5". I have to cut and tack in one small slice to the last primary, then I will remove the manifold from the car, and after marking the primaries relation to the flanges, break each one free and tig weld each individully. Finally, I will fit and weld each back onto the flanges.

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Old 06-10-2010, 09:48 PM   #45
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This has got to be the interestingest manifold I have ever seen.
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Old 06-11-2010, 03:26 AM   #46
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well, this is my second header--the first being an N/A equal-length manifold, with 28" primaries. The main reason for the long primaries on this one, obviously, is because of the front-mounted turbo. That is there because theres no way of cramming it in the traditional location.

And, while I've heard plenty of questions, I have yet to hear anyone explain why it wouldn't work, so ill run with it.

were I to be able to get an affordable, more streamlined turbine housing, I would have probably have located it elseware... but.......
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Old 06-11-2010, 01:07 PM   #47
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Oh, I'm not criticizing. I actually think that this is a really ingenious solution. Gonna have to get clever with the bracing, but I see no reason why this can't work.
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Old 06-11-2010, 02:20 PM   #48
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This **** is fantastic! At the risk of being called 'gay': I <3 creative engineering!

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Old 06-11-2010, 03:42 PM   #49
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I wast saying you were criticizing... I was referring to a diferent forum.
jfor the turbo out of 3/8 plate and bolted that up to the old cast A/C bracket. that shouldn't be going anywhere.

could one of the moderators please change the title of this post to something like "Now: Turbo Build Was: Thermostat Rerouting" or something of that nature?
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Old 06-11-2010, 10:06 PM   #50
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Wow Thats creative I like it, I really really hope you plan on Wrapping that manifold it will generate soooo much radiant heat under that hood

it should Last a very long time making it from Black steel plumbing pipe
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Old 06-11-2010, 11:51 PM   #51
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thanks.

yes, once I tig everything upn ig am going to brush everything and then spray it with hi-temp paint, and then eventually hope to wrap it with cf wrap.

I may make one or two naca ducts to allow some internal airflow other than the nosecone. im going to do just about whatever it takes to refrain from burning off the outside paint.

as for schedule 40, I was going to usual aluminized exhaust piping, but one forum mentioned that would destroy pretty quickly under boost. as I eventually intend on applying some serious boost, I might as well prepare for it.
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Old 06-13-2010, 03:17 PM   #52
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Joe, what were you referring to by bracing? the turbo or manifold?

im debating on welding the primaries together once everything is put together, but I am not sue if that will effect expansion or vibration.
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Old 06-13-2010, 04:12 PM   #53
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I believe he was refering to the turbo, hanging off the end of the manifold. And you still have the weight of the downpipe to go. BTW, what's the routing plan for that? And you may have mentioned it, but click "user CP" in the top left of the page and put in your location.
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Old 06-14-2010, 12:13 AM   #54
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The turbo's not hanging off the manifold. And as for the downpipe, it is only going to be about 25" of stainless 2.5 -- I am going to have side exhaust right behind the left fro bet wheel. I will still try to make some sort of hanger/bracket, but weight-wise, it should be efficient.

Here are a couple of pics of the turbo bracket. Im not very concerned of it going anywhere. Between the 3/8" bracket and the A/C bracket, it should be good.

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Old 06-18-2010, 04:44 AM   #55
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Thanks for posting. I've got a 7 and looking at conversion to a 1.8 and turbo and you are making it much easier to plan.
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Old 06-18-2010, 02:45 PM   #56
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Are you on the LocostUSA forums?

I will help however I can. are you using a book frame, or larger?

if using a better routed/flanged turbine housing or a smallr turbo, you could probably mount it more conventionally.
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Old 06-18-2010, 02:50 PM   #57
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sure wouldnt want to have to replace belts on that motor.
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Old 06-18-2010, 03:13 PM   #58
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i mean i love ingenuity and all but having the turbo there just looks like a reason to get even heat soaking lol. Its all good though.
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Old 06-18-2010, 04:49 PM   #59
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the belts aren't that bad. it only takes four turbo bolts, four flange bolts, and the exhaut manifold bolts to remove everything.

and for heat management, I plan on wrapping just about everything and I want to see what I can do about a turbo hoodie.
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Old 06-18-2010, 05:02 PM   #60
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id get the piping jet hot coated
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