Honda S2000 turbo manifold, exhaust.. etc build

Here's something I've been working on with my friend.

heres a few pics of the kit being made.

making a temporary jig to hold the turbo where we want it.


20 hours later and the manifold, dp, exh system, boost piping is done. i did take pics of the process inbetween, but thought i'd load the best pics.



heres some pics of the turbo kit on a mock engine we had lying around.







we ran out of straight sch10, and had to make do just to get the manifold complete, but the long section on no4 will be gettin replaced.


heres pics of the turbo brace/manifold support




another triangular gusset will be added for further support.

the collector clears the bonnet/hood with about 10mm to spare. an oil filter relocator will be needed with this kit.
best of all, a 4 inch d/p will fit aswell, but the customer specified a 3 inch dp and exh.
the turbo hangs 7mm from the chassis cross beam, and theres lots of space for the wastegate.
best of all, there are only 2 boost pipes, suprisingly, you can manoeuvre the boost pipes into place, even though they are such long weird shape pieces.

material used:
sch10 3mm for the manifold
cnc milled 12mm stainless turbo and manifold flange
2.5 inch stainless hot side boost piping
2.5-3 inch stainless cone and 3inch cold side boost piping
3 inch stainless dp and exhaust.
6mm stainless turbo brace.

all TIG welded, and manifold will be back purged.

Pic of the JIG







Root pass



Flange welded up


Downpipe flange




Welding the elbow onto the collector. Back purged of course.





Welding the inside of the of the T3 flange.



One runner welded up. Thought it would be best to start with runner 3 first.



Second runner welded up.



Third runner welded up.






Sorry for the bad quality pics. Just have a phone camera on me.

Thanks for looking.

Nice work.

That weld down between the four pipes on the collector looked tricky.

Thank God my old cars are quite happy with a bit of pipe with a silencer in the somewhere in the middle.

Great work. Are you going to find a market for a few more now that you have sorted the design and jigs?

Andy

Great stuff! From the colour I thought you'd done it in Ti at first!

Wonder what a S2000 turbo would be like? Any details of the proposed engine spec?

Now this is how I like to start a Friday morning!!

Excellent work!! GT3076R is it?

Ant

Fabulous stuff, very impressive!

Camera phones are great, nothing wrong with the pics its all thats needed to show work. Realy nice job done, if you have it all jiged you may aswell make a couple more as they would sell for quite alot.

Nice work, don`t suppose you were at JAE, there was a nice s2000 turbo there, i think it was running a GT35R, nothing much until 5krpm but then al hel broke loose, dyno printout showed 580 ponies

You'd think it would need a less lumpy cam, or radical tweaks to the Vtec. 700 is certainly possible from the MR2 lump.

It's not my car but a customer's car.

He wants about 350hp to start off with as he's only got a standard engine.

I am looking to offer this kit up to some other s2000 owners. Once I get more straight sch10 pipe I can finish this manifold.

Thanks for the kind comments.

vtec_lude said:

Thanks for the kind comments.

Click to expand...

You deserved them, every last one! Thanks for the pics!

Lovely work that.
Reservations on the individual tube lengths its common practise to have them all the same lengths, just check.

Look like very good workmanship gone into that, nice job!

Only comment i'd have is that the inlet and outlet hoses on the intercooler are very sharp for fast moving air, so if there's clearance, try opening up the angles abit, otherwise excellent!

Thats going to be one fast S2K! Is the engine going to be rebuilt?

hareng said:

Lovely work that.
Reservations on the individual tube lengths its common practise to have them all the same lengths, just check.

Click to expand...

I wonder if this matters so much where you are feeding into a turbo. 100% agree with a standard exhaust.

Andy

Yep, pretty sure some manifolds with un-equal lengths seem to produce better response without any real hit in power, thats why the manufacturers do it, improves drivability and keeps the turbo spooled, thus making is smoother. Hope that makes sense? Not to good as technical description!

My understanding was the other way to that. Equal length runners give you smoother operation as each pulse is equally spaced. Un-equal length gives you the sound of a scooby because pulses are colliding and giving a: bang bang BANG ba-bang bang BANG type effect.

I would certainly agree that having an equal length manifold is very important for a non-turbo engine, but not so much for a turbo application.

More progress. Pretty much done now. Just the Wastegate to weld on.

Well after 20hrs of welding it's pretty much done now. I think I need a lie down.

This car gonna be at any shows next year? Would love to see it in the flesh once its all up and running.

cool welding, ive seen this on cliosport

nice pipes, i have question no welding related honda engines do they all fit the rwd gearbox