Fabricating an exhaust manifold

[Davebell]

Im thinking of turboing my clio and the most awkward part is getting a manifold,
the only manifold freely available is a cast one which is of bad design and rather expensive at that! I have an old tubular manifold for the same series of engine kicking around and was thinking of making my own turbo manifold, we have a water jet cutter next door to my work so flanges arent going to be a problem, however making the bends out of tube is going to be the hard part, is there anywhere i can buy pre-formed bends? i.e. 90 deg 45 etc? also Exhaust temperatures come into play, do i need to allow for serious heat??
it hasnt got to look show its simply for go

Dave

 

[madkayaker]

There is a great thread about making one on here. Try searching. I'll have a look and post the link when i find it.

 

[madkayaker]

http://www.mig-welding.co.uk/forum/showthread.php?t=8575

This is what i was talking about. Very good photo's and expalantions.

 

[Davebell]

Yes just read that, got heaps of Sch10 tube and bends at work actually! dont think stainless would be the best option for my first attempt though, Rather expensive when you mess up! has opened my eyes somewhat

Thanks
Dave

 

[madkayaker]

glad to help. Try getting some stainless wire and some scrap for a practice! Plenty of people on here who can give pointers.

 

[Archie]

Jetex sell all manner of preformed bends for exhausts.

 

[JayRS4]

Jetex sell all manner of preformed bends for exhausts.

Or if we`re keeping it within the forum, Fin from here (www.dynoflow.co.uk i think) will sell you stainless ones, don`t know how prices compare.

Wonder where he`s got to actually, havent heard from him lately

 

[Pete.]

Im thinking of turboing my clio and the most awkward part is getting a manifold,
the only manifold freely available is a cast one which is of bad design and rather expensive at that! I have an old tubular manifold for the same series of engine kicking around and was thinking of making my own turbo manifold, we have a water jet cutter next door to my work so flanges arent going to be a problem, however making the bends out of tube is going to be the hard part, is there anywhere i can buy pre-formed bends? i.e. 90 deg 45 etc? also Exhaust temperatures come into play, do i need to allow for serious heat??
it hasnt got to look show its simply for go

Dave

If you're migging it make sure you check the inside of the tube joints to prevent any wire stick-through from coming loose and wrecking your turbine wheel. Turbos spin at <150,000rpm so it doesn't take much to destroy one.

 

[V8-108]

Another supplier of stainless bends is Lance Pritchard at 0JZ Engineering
He is very knowledgable too if you need any advice. He made me some great exhausts for a pair of Suzuki TL1000s in the back of my grasser, beautiful TIG joints.

Neil

 

[Pete.]

That link throws-up a warning here by internet explorer about intranet settings and the page becomes unable to load.

Edit: I see what it is - your link needs editing it has two lots of http at the front.

 

[V8-108]

Thanks, and sorry Pete......all should be sorted now!

Neil

 

[Davebell]

Thanks for the advice, especially about the turbo vanes, Will probably tack it together using mig as im using a cylinder head as a jig (it needs to come up above the back of the engine pretty much) and then get a pro to weld it properly,
Dont Suppose anyone knows where i can get the dimensions of a turbo flange to suit a t28 turbo?

 

[Pete.]

Most of the T2 housings use a similar bolt-pattern, here is some measurements I found on another site: (Garrett T25 mount flange four attachment STUDS are on rectangle 72 mm x 40 mm c/c apart - typical flange outside dimensions are approx. 92mm x 62mm) though it wouldn't take long to knock-up a CAD drawing.

One thing I can help you with though, I did once have a CAD drawing made for the outlet flange on the T28. I had mine cut with a water-jet cutter. I can't find the drawing but I know I've emailed it to several people so it shouldn't take long to recover. It's a very good fit on the T28 turbine:

 

[Davebell]

Pete if you could find it, it would be great, we have a waterjet cutter next door to my work and autocad at my work

Cheers
Dave

 

[vtec_lude]

Hi Dave,

Definately use sch10 if you can. If you don't want to use stainless then sch40 mild steel elbows are your only option.

t3flange.com has a t28 dxf file on it so you might be able to use that.

Good luck with making it.

Also miggin it should be fine.

 

[Fin]

Or if we`re keeping it within the forum, Fin from here (www.dynoflow.co.uk i think) will sell you stainless ones, don`t know how prices compare.

Wonder where he`s got to actually, havent heard from him lately

Im around, always around somewhere on the web..Just very busy at the moment with the workshop and component sales. Been doing lots of work for the 750Motor Club stock hatch racers (They have to fit Cats in 2009)

 

[JayRS4]

Good to see you back Fin, the`ll be an order coming your way soon too. Probably best via PM but someone here may be able to answer anyway, what`s the best way of making flanges, be they manifold or mid exhaust?

 

[vtec_lude]

There are a few options.

1 - Cnc Milled
2 - Laser cut
3 - Water jet
4 - Plasma cutter free hand
5 - Angle grinder, lots of time and a few hole saws

 

[JayRS4]

Think it`s going to be the good ol plasma, although i`m going to look into water jet cutting prices as there will be a few repeats

 

[Tino]

I hope this link works, may be of some use.http://www.milneroffroad.com/PIPE.HTM#perf