Why not run a square flange?

Material is cheaper than the cost of machining so it should be cheaper.

 

heres mine. nothing speciall just 1.5" weld els. this view is from under neath so you can see how i reversed the #2 runner into the turbo so the airflow is better into the turbo intake from the log.
http://carphotos.cardomain.com/ride_..._large.jpg?v=0
top view showing the flange for the IHI VF10 turbo from a subaru legacy GT.
http://carphotos.cardomain.com/ride_..._large.jpg?v=0
here it is on the car. Very tight compac manifold. note the relocated power steering intake hose.
http://carphotos.cardomain.com/ride_..._large.jpg?v=0

this manifold has been on the car for 7 years now and not missed a beat! i havent even had to retorque the turbo or manifold studs and nuts!

 

I like to take off weight off the flange where possible as opposed to adding it on. I cut my skinny flange and welded up a manifold and it worked out well with no warping as I use 9 bolts and a strong plate to lock it down.



Strange as it is but I pay for laser work by the Kg so it doesn't hurt to add a few curves.

4sfed5 your manifold is what inspired me to try and make my own. It is an elegant design. +1

 

Thanks!
I just wanted something simple that wasnt going to crack, so fancy equal length manifolds were out. yours looks great too.

Subaru turbo FTW!

 

Does anyone have an opinion on whether I should put a relief cut in my mani or not?

 

Long time ago manifolds didnt have relief cuts. Since then i remember lots of them cracking. I'd add them.

 

looks really good work!

 

This is the start to an interesting series where a log manifold is constructed for a TD04. Note the asymmetrical outlet flange location to move the Turbo forward. This also discusses how to clock turbine AND compressor to allow wastegate controller to not need a new bracket. Of course, it limits the direction of the compressor outlet.

 

Anyone have a CAD file for a 1.6 flange? also need one for a T2 if available. i would PM the few that have mentioned it but i cant. :(

 

If you have cad, just run the exhaust gaskets through a scanner, xref the scanned tiff in, scale it off a few points and then trace it.

Print off a 1:1 scaled print of it to verify and your gold. shouldn't take more than 15 minutes.

 

i dont have CAD. i was looking for a drw file to take to my local machine shop to see if they would cut one for me.

 

download the free trial version from the autodesk website.

 

Many shops actually can use pdf files. You just need to give them some dimensions so they can get the scale.

 

I am starting to gather parts.


Should I get the HF 12ton press to help crush the weld els together or another bigger stronger vise. I broke my 4" HF vise today trying to crush one.

 

Get both.

EDIT: you can crush anything with enough heat. I used the press and no heat though. Easy to go a little at a time. Which I have to do.

 

I bet the vice made you jump when it went

 

Pansy, I crushed mine with a big hammer and a concrete floor.

 

I used HF press... Oval'ed them all in under 5 minutes probably.

I have the smaller press I think? I want to say I got it for <$90. Look out for the deals and if the 20%-25% off coupon works with it.

 

Oooh. Like this.

 

First manifold is getting there. I am learning how to use my new HF band saw so my cuts are by no means perfect yet. Tomorrow hopefully I will get it all good gap wise and get some tack welds on it.