Custom manifold, downpipe, and exhaust build
16 Attachment(s)
Thought I would throw up some sequential pictures of the turbo setup I just finished and installed about a week ago. I used hf-mx5t's manifold as inspiration, because I wanted it to be a short tubular manifold with the same turbo mounting position as my previous manifold (low mount). I made a jig from the previous manifold to hold the two flanges in place so that I could work on the manifold without the car.
It is completely tig welded, and I used mcmaster carr steel 1 1/2 inch bends to make the manifold, some short radius, some long radius. I had the manifold ceramic coated afterward. The downpipe and exhaust is full three inch all the way, steel also. Next setup will be all stainless. I started by making the manifold out of toilet paper rolls to help me visualize the whole thing and see how it would go together. Attachment 190467 Attachment 190468 Next I made the front and back halves separately, so I would only have to deal with the collector two pieces at a time. Attachment 190469 Attachment 190470 Then I cut each half to fit them together, and welded the manifold up. Attachment 190471 Attachment 190472 Then I sandblasted the whole thing and drilled the hole for the watesgate and welded the flange on. I bought the wastegate used, and i thought i should machine out a slot for the little protruding ring to fit into, can you guys see that? In hindsight i think that flange is supposed to be flat to push the ring up to seal. I had to put a gasket on the flange into the wastegate to make it seal. Attachment 190473 Attachment 190474 Done picture, and one with air box and filter back on, my favorite. Attachment 190475 Attachment 190476 Downpipe all tacked together ready for welding. I still need to put a flex tube into the wastegate part, anyone know where i can find a 1.5 inch flex tube? I couldn't find one from a place I trusted online. Attachment 190477 Exhaust pieces, a picture of how close it was to make the 22 inch magnaflow fit, a final exhaust picture, and a v band weld. The muffler was completely worth the hassle of fitting it in there. Attachment 190478 Attachment 190479 Attachment 190480 Attachment 190481 Attachment 190482 Overall, I love it, it spools way faster than my old log mani, internal wastegate, and 2.5 inch exhaust. |
Damn dude, super nice work.
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Looks really good, almost like a flipped ETD manifold.
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Great DIY work man
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Great stuff, thanks for sharing!
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awesome! Wanna help me make the v-band exhaust when the time come? I have the same magnaflow muffler.
- Jason |
I really like your exhaust. It is one of the best looking ones I have seen.
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loosen off the vband and level out that muffler.
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Thanks for all the compliments guys.
Jason I'd love to help out, pm me when the time comes. You have a place to do it? We can use my garage if not, it's doable to make a whole exhaust in a day. Shlammed- I would, but the v band is too far down by the diff that the other parts of the exhaust would hit stuff if rotated. I would have to add another vband and change the hangers a little bit, I will probably do this when I do the rest of the changes late march. ( adding flex to wastegate tube) |
that is a nice looking manifold. great job!
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Okay, I will PM you when I get everything together. I have a garage but no 220v outlet in my garage.
- Jason |
Awesome!
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Nice job! Lookin good.
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Impressive
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Nice job, looks clean.
Can I ask why you welded the hangers to the thin part of the muffler casing and not the thicker endcaps? |
What?! no cardboard manifold?! weak. no balls man.
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Originally Posted by mx592
(Post 801071)
Nice job, looks clean.
Can I ask why you welded the hangers to the thin part of the muffler casing and not the thicker endcaps? Since that build, I've built two more exhaust systems with the same muffler, both times I welded the hangers to end caps and made the entrance to the muffler shorter. Every new setup i learn something new :). |
Impressive!
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Very nice work. I love the external wastegate position. If I ever went tubular mainfold, I'd do a similar setup.
Great job! |
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