Got 2 days and nights to build entire hotside setup.
 

Hey guys,

So the car with the GT2560 that made 297 on an AVO manifold and dump has a cracked manifold.
I knew it has an exhaust leak but never expected this.

Due to an event which has already been planned and paid for the owner has given me 2 days to remove the engine, build an entirely new hotside and exhaust, refit the MS, tune EBC and get it to the track.

It has no PS or AC and is a 1.6L with a 2560

Please blast me with photos of manifold and suggest what I should build.

the car was going to be left with me for a month in order for me to take my time and build the best setup possible and see what a 2560 could make running all of it on a fully worked built engine on E85 but alas this has happened.

This is the setup it has made 297rwhp on.

http://i49.tinypic.com/14uev0l.jpg

https://www.miataturbo.net/attachmen...ine=1353916207

Thanks for everyones help,
Dann

I'm confused, this is a friends/customer's car that broke while you were tuning it and you need to fix it? He was giving you a month, then it broke, and now you have 2 days? Is the motor already out like in the picture?

Here's mine, since you asked.

https://www.miataturbo.net/attachmen...ine=1353918641

https://www.miataturbo.net/attachmen...ine=1353918641

https://www.miataturbo.net/attachmen...ine=1353918641

He's a friend of mine. the exhaust leak was noticed a week ago, after a 1km drag event.

The car was given me to have the ECu reinstalled and the EBC tuned, its monday night here and he is leaving for the weekend thursday morning. It was to be job done on a free evening.

While going over the car in preparation for the weekend for him Ive found the cracked manifold. This weekend was to be the last event that the car was driven on this setup.

It was to be raced like this, and then left with me for a month to build a new setup in my own time.

Now I have 2 days to build all the hotside gear.

Im hoping someone car give me some ideas as to what I can build quickly, so that I dont have to build a setup that runs for only one weekend, and then rebuilding it properly.

yes I removed the engine this afternoon in preparation.

Dann

Weld up the crack? Its cast so its not going to be super easy. But I'm sure he'd rather have you do a quick fix on it than try to slap something together in two days that you were planning on making in a month.

A log like curly posted will probably be easiest and fastest.
Next up would be a smoother 4-2-1 log using els that would probably flow better.

IMO those are you only choices for something simple and easy to make.

Why not just weld the sh* out of the cracked current mani, have him race the car for the 1 day, then build a good setup without being rushed?

*edit: Leafy beat me to it.

Ho Lee Schitt, you're agreeing with Leafy? What is is this world coming to??!?!?

You ever welded cast before?

It doesnt melt it just disintegrates.

Dann

"has" being the operative word.

I thought the same thing as I edited the post:giggle:
Yup.
Its possible. Not easy or ideal, but possible. In most cases anyway.

I'm a neophyte when it comes to welding, but can't you just braze the manifold enough to fill the crack, run it for the event, then take your time like these guys are suggesting?

Maybe fab up a brace for the turbo while you're at it to take as much strain off the manifold/braze as possible?

The "Build me a manifold and a downpipe in 2 days" kind of customers are why I don't build cars anymore. Inevitably he won't be happy with the results, and it will reflect poorly on your skills as a fabricator. Fuck that noise.

In order of preference:
-Weld the crack (try this first no matter what, since the manifold is already ruined)
-Buy used OTS FM/BEGi parts, overnight parts in, then sell post-event
-Fab up a super-cheap log manifold and use his current downpipe
-Tell him to skip his event

Rent a Spec Miata.

Tell customer to go back to stock. Slower class is more competitive.

just curious. know anything about the inside of the motor ? stock internals or running forged goodies ?

You're doin' it wrong.


Properly weld the crack and return car to customer.



http://www.lincolnelectric.com/en-us...on-detail.aspx


Select the correct rod and follow the guide. Drill and v-out the crack, preheat the crap out of it, weld with correct rod, let cool in a bucket of Lime.

V is a great tip!

Hes a good friend of mine, So if he wants something better than I can slap together in 2 days there's no hastle having him remove it and sell it and have me rebuild it all.

I think Ill build an AVO replacement straight up as fast as I can, and leave it there incase I cannot finish the rest of what i want to do.

That way at least all of the rest of the AVO gear can be sold as a package down the track also.

Sound sensible?

Dann

Full built and worked, read the first post.

Dann

Heres what we went with.

It will need 1 new hotside cooler pipe and a dump.

https://www.miataturbo.net/attachmen...ine=1354001186

Obviously this pic is at the start of the build. At this point not even the port shapes have been hammered out of the steampipe.

Im doing a 3" downpipe and a 3 foot long straight pipe for the exhaust. It will do for the weekend.

Thanks for everyones help, it will hit the dyno tomorrow arvo cos I suspect it will spool a lot better than the old setup and will need a work in its new found area under the curve.

Ill post what it makes. Then Ill sell the setup.

Dann

Interesting as I have the same AVO manifold with similar damage and was looking at going down the "steampipe" route.

What did you use to cut for the turbo flange? The pipes I had temporarily are mega thick... maybe too thick for Dremel and the hole is too small for angle grinder... Eek!

Wow, nice quick start there!!!!

Post the results when you're done. :D

Ok heres a direct copy and paste from another forum.

So I was going over a mates Na6 on monday evening (casper) to find an exhaust leak and give it a once over before a track day I found this.

https://www.miataturbo.net/attachmen...ine=1354103951
Cracked manifold.

With plans of a whole weekend racing and leaving on Thursday, the question was asked how to get the car ready.
We could try and find another turbo kit 2nd hand, hunt another cast AVO manifold, or build a whole new turbo system from scratch.

So out came the engine.

https://www.miataturbo.net/attachmen...ine=1354103951

And some steampipe is tacked together to trial fit the turbo.
https://www.miataturbo.net/attachmen...ine=1354103951

Comparing a 3" V Band dump to the AVO one. Ill provide more photos to the guys who think that AVO dump is good, I will prove that its very close to 2".

https://www.miataturbo.net/attachmen...ine=1354103951

Welded up the manifold.
https://www.miataturbo.net/attachmen...ine=1354103951

Today I built every turbo related component you can see in this picture. Oh yeah, forgot the engine back in step lol.
Oil feed line and all.
https://www.miataturbo.net/attachmen...ine=1354103951

Heres a good look of the 3" Stainless Steel V Band Dump pipe, note the gorgeous food grade Reducer cone, Finally get theses for under 100 dollars.
https://www.miataturbo.net/attachmen...ine=1354103951

And some welding pr0n.
https://www.miataturbo.net/attachmen...ine=1354103951

In the above photos look again, compare my weld to the one on the flange done by the shop who built the exhaust. And then have a quick look at my finger prints for scale.
Tiny pulse weld.

So tomorrow it will get tuned in Canberra, and it will run wakefield all weekend, then it will be removed for a big tubular exhaust manifold and bigger exhaust next week.

So thats the answer to what can be achieved in 2 days and evenings.

Oh and one last thing...

https://www.miataturbo.net/attachmen...ine=1354103951

https://www.miataturbo.net/attachmen...ine=1354103951

:shock:

Dann

Very nice on that borg. But I thought you were going to shoot for 350 on the 2560?

Still am, this is getting tuned tomorrow, raced all weekend and then brought back to redo the entire thing again.

Go up to 1.5" runners, low angle merge, 4" exhaust straight through cos I can etc.

Dann

Ok cool. And then afterwards the BW EFR is going in?

Thats for a different car, but yes I intend to build the manifold EFR friendly and a little EFR will go on later.

Dann

I wanted my reply to adequately reflect the level of expectation found with MT threads but Oh Baby, I just peed me pants.

Nice work Dann.

Gatdamn dude, quick and great work.

So finished it off this morning, MS arrived in the mail. Connected laptop, dumped in the old tune, started first go.

Awesome.

Dann

Very cool. Post up dyno plot when you take it in

Is there a flex pipe somewhere in the exhaust? o_O

I tried to convince him to just run the dump pipe, but he said he was worried about volume so asked me to add that cone reducer and adapt it to the old 2.5" exhaust. The dump exhaust has a flexible straight after it bolts to the downpipe. I also put a brace from the end of the downpipe to a bolt on the gearbox.


it's getting good tuned right now.

Dann

So its at a dyno 5 hours away and they are having some issue.

Said its only running 7psi, I knew that the boost controller was fully open and the wastegate can is a 7psi one. So it should have been 7psi but then the tuners said the boost T was broken (its a turbosmart T with like 20km on it.)

So the tuner fitted a new boost T, then decided he didnt like how it shared the same vac hose as the BOV.

Then he said the BOV was opening at 7psi causing only 7 psi of boost.

So he removed the BOV vacuum line, then he said he was sure it was dumping boost.

Then he said the wastegate was opening too easily and that was why it wasnt boosting more than 7psi.

Its been line 7 hours at the dyno and still havnt figured it out, Sucks I couldnt make it.

Fuck this.

Anyways.

Dann

Did you get the turbo used or did full race send it to you with all the goodies already installed? I see the upgraded BOV plate and the upgraded full race wastegate.

Hi Dann,
Just wanted to touch base as I see your in Newcastle (can't send PM's yet).
I am up on the Gold Coast and looking to build a BP with one of the new BW EFR turbos. And I will need some manifolds fabricated.
As such I would be very interested to see how you attack the one you mentioned.
Like I said I look forward to seeing your results.
Cheers
Justin

Gday Justin, I've got a long thread over at mx5cartalk.com iI updates with fab work.

The efr is new but the efr isn't on the car, look at the pics it has the same 2560 its always had. Nothing has changed but the turbo manifold (still a log design though) Nd the downpipe is much bigger.

Dann