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DIY manifold

Old 06-21-2012, 12:44 PM
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Good. Sometimes it's real easy to come off like you say, with a fingernail even. Sometimes I have to grind it off.
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Old 06-21-2012, 12:57 PM
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I've had my fair share of PITA time with crap mild steel before welding. I learned my lesson well. The coating didn't look bad to begin with, pretty clean and slag free. I cleaned it with acetone, then sanded it down with a nice fresh disc on my DA then cleaned with acetone again. After that, it welded perfectly fine. Right now my goal is to get as much of the pipes welded as I can, break the pipes back off of the head flange, weld whatever I couldn't get, reclean everything and then finish weld the pipes to the head flange.
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Old 06-21-2012, 01:00 PM
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Originally Posted by sturovo View Post
Pics or ban!
bro I've been to Bratislava, there are some DISGUSTING vaginas there
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Old 06-21-2012, 01:54 PM
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The kind thats washed in a bucket?
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Old 06-21-2012, 05:19 PM
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Why are we talking about icky icky vaginas now?
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Old 06-21-2012, 05:52 PM
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Originally Posted by pusha View Post
bro I've been to Bratislava
And we have the photos!
Attached Thumbnails DIY manifold-pushanbrat.jpg.jpg  
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Old 06-24-2012, 11:59 PM
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I've managed to run down the friend of a friend who has a CNC Plasma Table.

More details as they come.
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Old 07-08-2012, 08:17 AM
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Any updates on manifold fab?

(Or is it just too hot to work like here?)

Originally Posted by pusha View Post
bro I've been to Bratislava, there are some
Pusha, are some of your girls here?
Wall Photos | Facebook
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Old 07-08-2012, 01:39 PM
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your mild steel, so this doesnt matter, but i thought this was a neat purge thingmajig for ss: The Absolute Best: Part II~ | DOC Race

very interested to see how turns out.
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Old 07-08-2012, 02:58 PM
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That is a pretty neat do-dad. I didn't have the equipment or budget to back purge, so it will just have to be fine without it. I've been working on the manifold, but it's all been finish welding. I've gotten the whole tubular portion finish welded. Now I need to order a carbide burr to take off some of the nastier edges inside the runners before welding the runners to the head flange for the final time. After that, it will be done until I can tear the car down and figure out the final placement of the turbo before welding the turbo flange on for good.
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Old 07-21-2012, 05:02 AM
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another option for clocking td04 wastegate linkage as seen on ebay
Attached Thumbnails DIY manifold-untitled.jpg  
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Old 07-21-2012, 06:00 AM
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I betcha "it's malfunctioning" a bit.
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Old 07-21-2012, 01:03 PM
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Wow, that's awesome. I haven't figured out exactly how it's going to be clocked yet. But I think I will probably end up just welding something to the cold side housing that I can drill and tap.
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Old 07-21-2012, 03:25 PM
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You do know that the linkage doesnt work right?
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Old 07-21-2012, 04:44 PM
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No way... that crazy bent up ebay crap doesn't work? Yeah, I guessed that it works about like it looks. I still haven't quite figured out how to mount the actuator though.. just thinking out loud.
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Old 08-02-2012, 11:46 AM
  #116  
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So, where are you now?
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Old 08-02-2012, 03:45 PM
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Why no external wastegate? Then you wouldn't have to worry about linkage for the actuator...��
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Old 08-03-2012, 12:08 PM
  #118  
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I haven't made any progress in a while. Life kind of got in the way. I still need to buy a carbide burr to port the exhaust housing on the turbo and clean up the inside of the runners.

I'm not doing an external gate for 2 reasons: 1) The main point of using a WRX turbo is the setup being super cheap to build and wastegates are expensive. 2) I like the simplicity of an internal gate.
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Old 08-03-2012, 01:36 PM
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Originally Posted by RyanRaduechel View Post
Why no external wastegate? Then you wouldn't have to worry about linkage for the actuator...��
Making a flat bracket that properly moves the actuator is much easier than fabbing exhaust and a manifold and buying an external wastegate and putting it all together. If it works why make it more complicated?

Its kinda like saying hey i have a megasquirt however instead of changing the tune it i'll just install a whole bunch of bandaids to fix my fueling issue.
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Old 08-04-2012, 12:50 PM
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It's not like saying that at all. That's like saying external wastegates are band aides and internal would be the MegaSquirt. A band aide would be porting the wastegate on the turbo (band aide) to prevent boost creep, the proper solution is going external wastegate (MegaSquirt). And please enlighten me on how it's so much easier when the guy is already building his own manifold? Not trying to be a dick but I don't find your comparison to be accurate.
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