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DIY Turbo Discussion greddy on a 1.8? homebrew kit?

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Old 01-23-2009, 11:00 PM   #41
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Ok I finally got some pics. These are cell phone pictures so I apologize for the bad quality..

KEEP IN MIND: My dad recomended I use mig and not tig, since mig can take on a much thicker metal. Also, this is one of my first tries at actually welding something together (for actual use lol) so the welds are nowhere near as good looking as if my dad (welder) can do..As long as it holds good I'll be happy, and it should hold.




as you can see, though the welds are not pretty, they are friggin massive and penetrated the steel completely, so I seriously doubt it will crack.

this is after a couple minutes with a wire fitting and the grinder:



cant really see it, but I took the dremmel to the inside and smoothed everything out for good flow:



on monday I will give it to my uncle, he will put it in a machine that will run crazy amounts of sand/liquid and other **** through the inside to make it completely smooth and perfect for flow. then the flanges go on and its good to go.

sorry its taking so long, I'm a lazy bastard and have limited time to work on it.

Last edited by 18psi; 01-28-2009 at 01:09 AM.
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Old 01-23-2009, 11:11 PM   #42
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Looks good to me. Did you grind between welding? It helps.
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Old 01-23-2009, 11:26 PM   #43
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actually I did not. I'll tell anyone that will do this in the future though: Stein is right, grinding/dremeling this **** is A ROYAL PAIN IN THE ***!!! this material is STRONG...ridiculously strong. it took me a good 2 hours non stop to smooth everything out on the inside and get it to where I liked it. I'm sure sandblasting it will help too, though its already really smooth. feeling the whole inside with my fingers I cant feel a single significant bump or inperfection.
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Old 01-23-2009, 11:45 PM   #44
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The key to welding is grinding. Root pass, grind, then lay a bead on top. Looks like you were making the weld too wide too. From not grinding it down. Either way, it will be fine.
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Old 01-24-2009, 10:37 PM   #45
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Are those ells sch 40? I've had no luck with anyathing less.
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Old 01-24-2009, 11:11 PM   #46
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Good job, definatly looks decent, atleast better than some of these SSAC manifolds I've seen. You think about ceramic coating it?
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Old 01-24-2009, 11:21 PM   #47
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Quote:
Originally Posted by fasteddy View Post
Are those ells sch 40? I've had no luck with anyathing less.
schedule 10 I think
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Good job, definatly looks decent, atleast better than some of these SSAC manifolds I've seen. You think about ceramic coating it?
nah. taking a wire fitting to it really cleans it up enough to look good, and I dont want to spend any more money than I have to on this thing.
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Old 01-24-2009, 11:33 PM   #48
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schedule 10 I think

nah. taking a wire fitting to it really cleans it up enough to look good, and I dont want to spend any more money than I have to on this thing.

Gotcha, I dont know if you posted what but was the initial cost on the kit?
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Old 01-24-2009, 11:42 PM   #49
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its not a kit. els are about 6 bux each flanges are 10 and 20. dremel bit about 20. lots of time spent grinding/cutting/dremeling/matching/welding and the actual wire as well as tri-mix for the welder? I'm not sure, but it adds up.

me and my dad want to start making these for people, though he'd be welding this time and it will look MUCH prettier LOL...if there is any interest in something like this I can definitely work out pricing to replicate this thing or do it to someone's specs. just a thought...I want to get my turbo setup together and running successfully for a while before I say anything though. From working with this metal I am very confident it will not crack, but time will tell. It certainly is strong enough, and I melted the **** out of it.
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Old 01-25-2009, 12:07 AM   #50
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Quote:
Originally Posted by 18psi View Post
its not a kit. els are about 6 bux each flanges are 10 and 20. dremel bit about 20. lots of time spent grinding/cutting/dremeling/matching/welding and the actual wire as well as tri-mix for the welder? I'm not sure, but it adds up.

me and my dad want to start making these for people, though he'd be welding this time and it will look MUCH prettier LOL...if there is any interest in something like this I can definitely work out pricing to replicate this thing or do it to someone's specs. just a thought...I want to get my turbo setup together and running successfully for a while before I say anything though. From working with this metal I am very confident it will not crack, but time will tell. It certainly is strong enough, and I melted the **** out of it.
Hmmm looks Great to me. I wouldn't worry about getting it running first.
Just bolt the manifold up and get the downpipe and turbo postion good. Then I am intrested in the price for a 1.8L.
You can sell a few and get money to finish it the way you want.
If the price is pretty decent, I might want a mani and a 3 In. downpipe, if yall decide to build them.

I don't need anymore power than the car has, but the 1.8 in the garage is just sitting there. And the ebay car mani is Cracked CRAZY.
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Old 01-28-2009, 01:07 AM   #51
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Finally finished it up. Well, for the most part. The last thing I need to do is clean the inside of it with a good wire bit. Or I'll just let my uncle put it through a machine at work that will make the inside smooth as a baby's bottom with sand/water (still dont know wtf its called lol, extrude honed?)

anyways:






I am very proud of it, because even though I had my dad's guideance and help, I did this on my own for the most part. Obviously letting him do it would make it much prettier, but I was going for strength and flow, and I think I achieved both with this header.

Hopefully this will be of help to people planning to go this route
-Vlad
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Old 01-28-2009, 01:13 AM   #52
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Looks good. I know what you mean about the DIY proud factor. I did a lot of stuff myself that would be 'better' had I bought a piece rather than making it myself. But I love that I did it myself.
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Old 01-28-2009, 01:14 AM   #53
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Also- You started this thread Dec. 27th. Only took a month.
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Old 01-28-2009, 01:21 AM   #54
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Thanx
and we literally spent 3 days working on it for about 2-3 hours a day. Working really slow...What can I say, we are lazy bastards
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Old 01-28-2009, 01:28 AM   #55
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Quote:
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Thanx
and we literally spent 3 days working on it for about 2-3 hours a day. Working really slow...What can I say, we are lazy bastards
Hehe, I know what you mean. Last two days I've spent ~2 hours working on a cold air box. I'm not very efficient at getting **** done, but it's fun. Everything takes me forever, but it's usually worth it in the end. That manifold you got should be bullet proof reliable. I wanna build one this summer. I just hate to ditch the manifold I got as I have so much damn time in it. Decisions....
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Old 01-28-2009, 01:30 AM   #56
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That is one sweet manifold.

If you start selling I would like a 1.6L/T3 single scroll version.
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Old 01-28-2009, 01:35 AM   #57
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Originally Posted by patsmx5 View Post
Hehe, I know what you mean. Last two days I've spent ~2 hours working on a cold air box. I'm not very efficient at getting **** done, but it's fun. Everything takes me forever, but it's usually worth it in the end. That manifold you got should be bullet proof reliable. I wanna build one this summer. I just hate to ditch the manifold I got as I have so much damn time in it. Decisions....
If you do end up doing it, I would try to make a longtube or ramhorn type manifold. If you do a shorty, it will be marginally better than the log you have. Might as well go all out...btw, I could have easily made mine twin scroll, just didnt really want to. something for you to think about
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That is one sweet manifold.

If you start selling I would like a 1.6L/T3 single scroll version.
Actually we are thinking about it. Like I posted earlier: once this is on and working for a bit of time and I'm confident in it, I just might replicate it a few times. My dad sure as hell wont mind. Well see
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Old 01-28-2009, 10:52 AM   #58
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I'd think the shorty tube would be significantly better than a log with the 1 and 4 runners pointing at each other.
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Old 01-28-2009, 11:18 AM   #59
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Awesome manifold man. My homemade log mani is nowhere near that nice but has served me well.
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Old 01-28-2009, 08:17 PM   #60
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thanx
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