New Manifold and DP
 

In the quest for more power and better spool I needed a new manifold and definitely a better down pipe. Wayne Curr is hooking it up with a replica Absurd flow manifold. I would've gone with Tim but he dosen't make 1.6 stuff. I've already talked to Tim and he's cool with us replicating his. Tim's design is IMO the best design for spool and top end.

Before and after dyno numbers coming soon.

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cool beans. im itching to see the before and after dyno #s but more so the spool characteristics

Do Want!

This should flow way better than my old cast mani and down pipe.
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Very nice! You're definitely going to notice a difference with this.

Wow that looks awesome. Im really looking forward to see the new number as well.

Very nice. I've got something similar on my bench and a new tank of argon in my back seat for the snow day tomorrow.

EDIT: I could do 1.6 manifolds, just not the downpipes, and not for wayne curr's price.

Are you going to convert to an external wastegate?

Well start making them cause this is the first and last for me lol.

Actually I might make one for myself if I dont end up making a ramhorn. But that will definitely be the last one. These are a major bear to make in more ways than 5.

Not at the moment, I probably will eventually though.
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Or another like you made for me. I can't wait to finish putting my motor together and test my new one out

Ya or yours. All you mf'ers are making me jealous with your manifolds that are cooler than mine.

Teh sexorz, moar powah!

After that fourth photo above- is the next step for the flange ends to cut them straight across to fit flush on the flange face, or will there be more pipe making the connection to the flange? And isn't now the time to build the EWG setup given the project is in the works? Seems like the built engine and high boost are just asking for it. :D

300?

What? It's a simple straight cut. What can be so hard about it? I ram horn is sooo much harder to build........ :jerkit: People have no idea.

It definitely takes some serious time getting all 4 pipes pointed where they should be pointed. Off just a hair on the collector means off a bunch at the head flange. You'll be looking good while everything's tacked, then as you weld things may move (more with stainless). Then you smoosh the primaries into ovals...whoops things moved again. Fun stuff!

The straght cuts are simple. But exactly as you said, everything has to be dead nuts perfect at the collector or its all wonky at the flange. Right now I need more space between the turbo and the block so I have to lengthen the 2 and 3 runners and take the collector apart again and grind it so that 1 and 4 still line up nicely.

Stoked for before/after numbers. I bet you pick up 25whp and 500rpm of spool.

Should be better spool than that, depending on downpipe & making the collector flow into the T2 flange (duh).

Althought I spent all afternoon working on it, the pictures I took dont make it look any different than the original ones in the first post so i'm not going to bother uploading them.

I lengthened runners 2 and 3. Doing this meant I had to re fit the collector so the runners matched the ports in the flange. After all that I took the dremel and spent some quality time smoothing and deburring everything on the inside. I'm trying to make it as perfect as I can since all eyes are now on this project =P

In for results. looking teh sexay.

Id be extremely happy with that.
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um, new pics or ban. sorry.

I went from making 15psi at 4200rpm to 15psi at 3200rpm, lol. It also doesn't drop torque anymore as the RPM climbs.

I ran the car at 15psi two nights ago and it was SERIOUSLY fucking fast. Its like a different motor with 4 more psi. I don't see why people consider buying anything else.

Oh, and now I'm up to 14-hours of seat time on Tim's parts with no failure. :)

I'm loving all this praise from going cast to tubular. I can't wait to get mine running

How many people does this make now that have switched their mani/dp combos in the last year?

In for before and after numbers! :bigtu:

In for pictures and comparison numbers :)

Phew. Got distracted by the news this morning so didn't get to work til much later than I had planned but here is where I stand now. All that is left is to weld it! It lines up with the head flange near perfectly. I'll need to grind just a hair of overhanging metal from the inside of runners 2 and 3. As it sits i'm happy with where it puts the turbo in the engine bay and very happy with the way everything lines up. I dont have enough gas to weld it today though unfortunately and the store is already closed :(

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Yay!

DDopeeeee
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I wanted to use every last bit of gas I had before getting a new bottle so I actually got some welding done yesterday afternoon. Going to get more done today and get it tacked onto the head flange to start the downpipe. I have to finish this stuff so I can put my car back together because I need it this weekend.

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:drool: :drool: :drool: :drool: :drool: :drool:

Some more pics but of the manifold looking a lot more like a manifold.
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I lent my jack to a friend 100 miles away and was doomed to scissor jack usage to get the car on stands in order to begin the DP build. One look at the scissor jack and I had an idea.

Scissor me timbers!
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I welded a socket to the jack and use the impact to raise the car! Its better than a floor jack!

Edit: and I forgot to post up the pic of the beginnings of the downpipe. The DP will be done tomorrow.
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Now THIS, is a grade-A post :drool:

Only got through 90% of what I wanted to today but i'm out of cutoff wheels, my sharpie is dry and I lost my safety glasses.

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Lookin great! How big is that dp piping? Looks huge. I like the jack lol

3" bellmouth downpipe.

Nice work Wayne!!!!

Sweet! Deffinatly looking forward to the next dyno day!

Me too, I wish I could be there :(

So i've got a couple of questions. Phil wants the downpipe to extend past where the stock cat is but I haven't had a cat or a stock exhaust in my car for quite some time. Can anyone give me a reference point under the car (on a 1.6) as to the location of the cat so I can extend the downpipe to that point?

Also, Phil where is your WB02 located? I can put the bung where is convenient. I have mine hanging down from the shifter turret but it just has enough slack in the harness to plug into only one spot on the downpipe. Not sure if yours is near that or in the same place.

That looks awesome, great work.

Shoot I'm jealous....

I have my WBO2 in the same place and I'm pretty sure that in a stock setup the flange for the cat would extend just a few inches past that point. Can anyone confirm?
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That is where the first flange would start. Didn't you want this to extend all the way past the stock cat so you could remove it? Other wise I think its pretty much long enough as is.

I haven't made any progress on it today. Our OTM needed some major attention today so i've been working on it since its the girl's DD. I think the mani/dp should be shipping monday though baring any unforeseen circumcisions.

That's perfect, when I had my exhaust made I had it made to mate right up to the dp.
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Well i've got the downpipe all done and tacked up. Its got a lot of straight pipe after the flex so you'll have plenty to work with however you decide to have it mated to your exhaust. I'm really really happy with how it fits compared to my downpipe.

YAY!!!!!!!! Im next!!!!!!!!!!!!!

Some finished pics.

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They Darth Vader of Manifolds and Dps. Well done.

Fucking SWEEEETT! What did you paint it with?
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gangsta... next day air?

Its 1200 degree bbq paint. They were out of the 2000 degree stuff so this isn't going to last forever but I just cant justify ceramic coating a budget manifold like this. Be careful installing it as it will flake off fairly easily til it gets some heat in it to cure it.

By the way, I didn't get it shipped tonight afterall. My girlfriend took the integra and there is no way in hell this fits in my miata. Goin out tomorrow morning.

If you pay for it.


No problem man.
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get this on before monday!

I highly doubt it will be here in time.
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Everything looks good. I didn't get any pretty black paint on my stuff:( It should be in in time. I think my stuff took 3 days to come in to Jax from him.

now, on to mine or insta-ban!

Ya I know. After seeing how good this looks after paint I really wish I had hit yours with it. Its cheap though, 5 dollars for a can of High temp paint. I highly recommend you do it.

Get in line son.

You don't think the paint is going to flake off after just a few hours of use?

Have you had good luck with BBQ paint on manifolds?

I painted my heat-shield with some and it did fine on that but the heat shield wasn't seeing quite the same temperatures as the manifold...

Well its rated to 1200 degrees. It will flake off easily til it sees some heat but after that I'd say it should last a thousand miles or so on the manifold. It most certainly is not going to last forever, its just rattle can paint no matter how you look at it.