Got 2 days and nights to build entire hotside setup. - Miata Turbo Forum - Boost cars, acquire cats.

Welcome to Miataturbo.net   Members
 


DIY Turbo Discussion greddy on a 1.8? homebrew kit?

Reply
 
 
 
LinkBack Thread Tools
Old 11-26-2012, 03:50 AM   #1
Elite Member
Thread Starter
 
Join Date: Apr 2010
Location: Newcastle, Australia
Posts: 2,638
Total Cats: 25
Default 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.





Thanks for everyones help,
Dann
Attached Thumbnails
Got 2 days and nights to build entire hotside setup.-200tz86.jpg  
nitrodann is offline   Reply With Quote
Old 11-26-2012, 04:30 AM   #2
Cpt. Slow
iTrader: (25)
 
curly's Avatar
 
Join Date: Oct 2005
Location: Oregon City, OR
Posts: 12,105
Total Cats: 518
Default

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.





Attached Thumbnails
Got 2 days and nights to build entire hotside setup.-41a82066.jpg   Got 2 days and nights to build entire hotside setup.-p1020282.jpg   Got 2 days and nights to build entire hotside setup.-p1020286.jpg  
curly is offline   Reply With Quote
Old 11-26-2012, 04:43 AM   #3
Elite Member
Thread Starter
 
Join Date: Apr 2010
Location: Newcastle, Australia
Posts: 2,638
Total Cats: 25
Default

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

Last edited by nitrodann; 11-26-2012 at 06:49 AM.
nitrodann is offline   Reply With Quote
Old 11-26-2012, 09:27 AM   #4
Elite Member
iTrader: (1)
 
Leafy's Avatar
 
Join Date: Jun 2012
Location: NH
Posts: 9,091
Total Cats: 90
Default

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.
Leafy is offline   Reply With Quote
Old 11-26-2012, 09:27 AM   #5
Murderator
iTrader: (76)
 
18psi's Avatar
 
Join Date: Apr 2008
Posts: 36,165
Total Cats: 2,573
Default

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.
18psi is offline   Reply With Quote
Old 11-26-2012, 09:31 AM   #6
Supporting Vendor
iTrader: (10)
 
Reverant's Avatar
 
Join Date: Jun 2006
Location: Athens, Greece
Posts: 5,440
Total Cats: 198
Default

Quote:
Originally Posted by 18psi View Post
*edit: Leafy beat me to it.
Ho Lee Schitt, you're agreeing with Leafy? What is is this world coming to??!?!?
Reverant is offline   Reply With Quote
Old 11-26-2012, 09:33 AM   #7
Elite Member
Thread Starter
 
Join Date: Apr 2010
Location: Newcastle, Australia
Posts: 2,638
Total Cats: 25
Default

You ever welded cast before?

It doesnt melt it just disintegrates.

Dann
nitrodann is offline   Reply With Quote
Old 11-26-2012, 09:35 AM   #8
Boost Czar
iTrader: (61)
 
Braineack's Avatar
 
Join Date: May 2005
Location: Chantilly, VA
Posts: 72,813
Total Cats: 1,780
Default

Quote:
Originally Posted by nitrodann View Post
This is the setup it has made 297rwhp on.

"has" being the operative word.
Braineack is offline   Reply With Quote
Old 11-26-2012, 09:40 AM   #9
Murderator
iTrader: (76)
 
18psi's Avatar
 
Join Date: Apr 2008
Posts: 36,165
Total Cats: 2,573
Default

Quote:
Originally Posted by Reverant View Post
Ho Lee Schitt, you're agreeing with Leafy? What is is this world coming to??!?!?
I thought the same thing as I edited the post
Quote:
Originally Posted by nitrodann View Post
You ever welded cast before?

It doesnt melt it just disintegrates.

Dann
Yup.
Its possible. Not easy or ideal, but possible. In most cases anyway.
18psi is offline   Reply With Quote
Old 11-26-2012, 02:03 PM   #10
Junior Member
iTrader: (5)
 
Join Date: Mar 2012
Location: Gilbert, Az
Posts: 337
Total Cats: 26
Default

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?
SJP0tato is offline   Reply With Quote
Old 11-26-2012, 03:13 PM   #11
Supporting Vendor
iTrader: (31)
 
Savington's Avatar
 
Join Date: Nov 2006
Location: Sunnyvale, CA
Posts: 14,353
Total Cats: 1,319
Default

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. **** 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
Savington is offline   Reply With Quote
Old 11-26-2012, 03:34 PM   #12
Tour de Franzia
iTrader: (6)
 
hustler's Avatar
 
Join Date: Jun 2006
Location: Republic of Dallas
Posts: 29,114
Total Cats: 351
Default

Rent a Spec Miata.
hustler is offline   Reply With Quote
Old 11-26-2012, 03:36 PM   #13
Elite Member
iTrader: (7)
 
Join Date: Jul 2009
Location: Gainesville,Fl
Posts: 3,354
Total Cats: 7
Default

Tell customer to go back to stock. Slower class is more competitive.
turotufas is offline   Reply With Quote
Old 11-26-2012, 04:23 PM   #14
Junior Member
iTrader: (-2)
 
Join Date: Nov 2012
Posts: 242
Total Cats: -42
Default

just curious. know anything about the inside of the motor ? stock internals or running forged goodies ?
Gt2560rMiata is offline   Reply With Quote
Old 11-26-2012, 04:27 PM   #15
Elite Member
iTrader: (11)
 
Join Date: Jun 2007
Location: Overland Park, Kansas
Posts: 5,382
Total Cats: 43
Default

Quote:
Originally Posted by nitrodann View Post
You ever welded cast before?

It doesnt melt it just disintegrates.

Dann
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.
elesjuan is offline   Reply With Quote
Old 11-26-2012, 04:46 PM   #16
Elite Member
iTrader: (7)
 
Join Date: Jul 2009
Location: Gainesville,Fl
Posts: 3,354
Total Cats: 7
Default

V is a great tip!
turotufas is offline   Reply With Quote
Old 11-26-2012, 05:23 PM   #17
Elite Member
Thread Starter
 
Join Date: Apr 2010
Location: Newcastle, Australia
Posts: 2,638
Total Cats: 25
Default

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
nitrodann is offline   Reply With Quote
Old 11-26-2012, 05:30 PM   #18
Elite Member
Thread Starter
 
Join Date: Apr 2010
Location: Newcastle, Australia
Posts: 2,638
Total Cats: 25
Default

Quote:
Originally Posted by Gt2560rMiata View Post
just curious. know anything about the inside of the motor ? stock internals or running forged goodies ?
Full built and worked, read the first post.

Dann
nitrodann is offline   Reply With Quote
Old 11-27-2012, 03:26 AM   #19
Elite Member
Thread Starter
 
Join Date: Apr 2010
Location: Newcastle, Australia
Posts: 2,638
Total Cats: 25
Default

Heres what we went with.

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



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
Attached Thumbnails
Got 2 days and nights to build entire hotside setup.-9gv6ug.jpg  
nitrodann is offline   Reply With Quote
Old 11-27-2012, 09:56 AM   #20
Newb
 
Join Date: Jan 2012
Posts: 1
Total Cats: 0
Default

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!
matt|H is offline   Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
Project Gemini - Turbo Civic on the Cheap Full_Tilt_Boogie Build Threads 57 07-19-2017 05:11 PM
WTB MP62 (Hotside) (NB2) Rick02R WTB 3 01-03-2016 08:18 PM
Leaky Wilwoods mx592 Suspension, Brakes, Drivetrain 1 10-01-2015 01:45 AM
K&N Intake Filter nbdooey Miata parts for sale/trade 0 09-28-2015 09:46 PM


Tags
fabrication, manifold, poz, sawzall, turbotim

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -4. The time now is 09:37 AM.