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DIY Turbo Discussion greddy on a 1.8? homebrew kit?

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Old 11-24-2008, 06:01 PM   #1
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Yep,

I need the CAD drawing of the 1.8 exhaust flange. I'm preparing something for you guys.

I did with a friend, a test for a ram horn equal lenght 1.6 manifold. Now the only thing that I have to do is to make the 4/1 merge, tack all everything and test fit it. My goal is to be able to fit a 3" complete downpipe. So may be I'll have to lower the turbo flange a little bit but that's not hard to do. If I do it for the 1.6, why not for the 1.8. I don't know what would be the cost right now but I'll try to stay under the 500$ for the manifold (100% SS, Fully TIG welded AND backpurged). For the DP we'll see this in time, I have to set the manifold before the flange.

But I have in mind to do a DP with 1/16" thick elbows so that would approach the closest to mandrel bent piping and after if the price is not too expensive, may be switch to a fully mandrel bent model.
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Old 11-24-2008, 06:03 PM   #2
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ohhh, Someone needs to get this too you, and post up pictures of the piece you are making for your buddy.
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Old 11-24-2008, 06:25 PM   #3
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Yep it's in development right now but the solidworks 3D drawing is here. Next the harder part will be to do the 4/1 merge collector but TurboTim (a great thanks to him) gave me plenty tips about it. The piece is for me. The buddy, he does the solidworks thing. Say thank you to this molding machinist! As you can see, I think the turbo flange arrives too high to be able to put the 3" downpipe. For block clearance I think it will be good though.

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Old 11-24-2008, 08:21 PM   #4
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I'm not sure what Rob is charging these days but Flipside was making manifolds exactly like that one. I heard rumor that he wasn't going to be doing anymore miata products but I could be wrong. I think he was closer to 7-800 for that manifold IIRC, maybe even more.
If you can do that for $500 you should be able to sell plenty. Specially if you add a forward facing external wastegate flange.
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Old 11-24-2008, 08:24 PM   #5
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Quote:
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If you can do that for $500 you should be able to sell plenty. Specially if you add a forward facing external wastegate flange.
+1, and some support braces.
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Old 11-24-2008, 09:46 PM   #6
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For the wastegate, no problem, just to pierce a hole, weld a little pipe with a flange and voilà. For the brace, I don't know what you mean Koto? To brace what exactly? That too should not be that hard to do either and won't affect the price.

I can checked too to make a log style manifold but I'll be honest: It doesn't cost much less in parts alone to do, just a little quicker to fab since there is no 4/1 merge to do. For that reason I won't fab them.

May be I'll check to do TurboTim style manifold but since he made them for some guys here, I don't want to steal his market and all that.
It's a good design without much parts but time consuming to cut all the pipes to make them go 4/1.
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Old 11-24-2008, 10:14 PM   #7
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For the brace, I don't know what you mean Koto?
like "qwkmx5" has on his manifold:



IIRC there are several (probably four, actually..)of the little rods like is visible in the pic running between the runners and the flange, to strengthen the part. I, for one, would happily pay the extra few bucks for a mani less likely to crack at the welds. If you bring this to market with complementary 3" downpipe and with an EWG option it might appeal to those of us looking to upgrade from our Greddies..
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Old 11-24-2008, 10:42 PM   #8
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I posted the flanges a while ago. Do a search. If you don't find it PM me and I will post the autocad drawing of the flanges.
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Old 11-24-2008, 10:43 PM   #9
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I hear you Koto! For the braces, wouldn't affect the price at all. I'll take the month of december to look at all this more seriously and make some test on my miata.

Loki, I'll look into it thanks
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Old 11-26-2008, 12:53 PM   #10
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Quote:
Originally Posted by Dark Wanderer View Post
Yep it's in development right now but the solidworks 3D drawing is here. Next the harder part will be to do the 4/1 merge collector but TurboTim (a great thanks to him) gave me plenty tips about it. The piece is for me. The buddy, he does the solidworks thing. Say thank you to this molding machinist! As you can see, I think the turbo flange arrives too high to be able to put the 3" downpipe. For block clearance I think it will be good though.


No problem buddy.

I'd worry a little about hood clearance. You'll probably be fine though.

EDIT: Actually on second thought, you will be fine.

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Originally Posted by Dark Wanderer View Post
May be I'll check to do TurboTim style manifold but since he made them for some guys here, I don't want to steal his market and all that.
It's a good design without much parts but time consuming to cut all the pipes to make them go 4/1.
Amen to that. If you wanna do my manifold, go for it. Do not underestimate the amount of time it will take to make those collector cuts so each runner points to the port it should. It's no joke. I ovalize my pipes at the head flange. When you smoosh the pipes, it changes the angles, so you have to account for that in the angles of the collector. You can end up with a nice collector that you spent a ton of time on that is junk cause one or two pipes won't line up with the ports in the head. muhahhaa

Plus I don't think many people want to get rid of their A/C and P/S so it may not be worth it to ya.

Go with the Vibrant 4-1 sch. 10 SS collector. Much easier to make the manifold fit.
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Old 11-26-2008, 01:54 PM   #11
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Actually, my friend said to me that he will be able to make the pieces for the 4/1 collector for the Ram model at his school so it will be pretty easy to weld them after that, and won't cost anything to me. I already thought about ovalize the pipes to flange but sch 10 is bigger than the flange hole. I checked and the best is sch 40. It lines up perfectly all around the hole. May be I'll do the 4 first pipes in 40 and the rest in 10, not sure about it.

For clearance, I think I'll be good, check the qwkmx5 manifold, Kotomile posted, it seems higher than my model

Still, for PS I got rid of it and I don't have AC at all so no problem for me. I don't know if it will be some clearance issue with the Ram model with AC and PS, I'll check with some of my friends here.

For now, I still have to get rid of the stock manifold and exhaust. Got the manifold and cat bolts off but bolt that attach the exhaust with the transmission won't come off. Little place to play there, anyone has a trick?
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