@. thanks for explaining especially the bit about the actual process of welding and the contraction. I said to the guy who done it to make sure it is bolted I dont think he did and it makes sense what has gone on. Just got to hope as well that he has not warped the turbo flange as well
Well if you pardon the pun I am exhausted at all the running around today spent a couple of hours trying to find somewhere with the required equipment to sort. Thought I found a place that does industrial bending, but they sent me to another local place that is more involved in the automotive side of things, they didnt have an oven so they couldnt do it, took it to an exhaust fabricator who also didnt have oxycetelene or an oven so they would have to cut the flange off but they are 5 weeks booked in advance also took it to a engine rebuild place who passed me to someone else. Gone one more place who came back and said they would mill the flange even though I explained and sent the below pictures so not sure about them now. I am convinced that I could do it with the required equipment alas that is not the case. Here is a link to google drive with the video but I think you guys have seen enough. Is anyone on here willing to take it on? Obviously dont mind posting it out if too far to drop off?
@. no offense at all. Guy who done it needs to sort it at his cost. The engines are not rare but the vehicle it is in certainly is. It is a true one off and I would not expect anyone else in the UK to even want to build a turbo people carrier. The parts to make one assuming it has been made from 2 tees and 3 elbows and a flange can be had for 145 dollars are pipes measured via internal diameter. TBF if it cannot be recovered then not sure I would go log style.but the dyno says it does work and I am at the limit on my current turbo and injectors but if at a later date I seek more power then obviously equal length would be the way to go. @Brad93 is that offer to make a new one or to recover this one? Template can be made from the gasket I tried to get a spare head before he done the job but couldn't source one so instructions were get creative so it is held during welding that didntt happen it was just welded without anything holding it at all :-( I wasnt at home when the guy done it otherwise would have stopped him.
@WorkshopChris stupid move it would now appear :-) @tom2207 engine under the seats (all the commercial ones available are for the s13 or s14 chassis) will have to see what is available bottom mount (most are top mount) and if it will fit as not much runner space, I had already thought along those lines. Here is what looks like a nice top mount that a guy in the states makes for customers $875
he made that from scratch, if I knew someone in the uk that could make one like that to fit in the space I have then that would be the answer for sure I have plenty of room underneath will get a picture and the downpipe could be modified as plenty of room there as well. Will post a picture or space I have shortly.
im sure some of the one off exhaust guys would be able to turn out one to suit ,, I can see how the price will be adding up though , although so far Im sure its not been cheap , on the other side of things as its not looked at under the hood , id not give up on what you have just yet ,,, granted its going to take a fix , and a bit of internal polishing ,, but its still all do able , even if its only as a stop gap till you do get a nicer job sorting out.
this might fit space wise but has the wrong flange. Plus i am external wastegate and screamer pipe. Think custom required but now car is disabled thats going to be a problem.
Stop being such a wuss... Lol
These lot are being proper negative. It won't take that much straightening.
Put it back together, it'll blow but it will drive, and drive it to someone who will make you a nice new manifold. Pick up car a few days later. Sorted!
12 week wait for the guy above :-) Manifold has been took by the guy who messed it up including gasket for tempate making. Watch this space its not going to quick and dont think pretty either cant polish a turd and all that. Here is another picture of what we are dealing with in space if tubular manifold is the future. turbo can be moved downwards.
Received a video of it bolted to a piece of heavy channel with 8 bolts thru it. On close inspection I could see that the heads of the bolts were substancially larger than the nuts were previously on it as the bolt heads were to the edge of the witness marks to where the washers were. I asked what size bolts were in the channel and the answers was 12mm yet I specifically said studs are M10 so who knows what hole size was drilled. The flange already had holes in it that had been elongated somewhat so the idea of the template has been lost IMHO. He had oxycetelene and got it cherry red the relief cuts he says are more aligned but when laying the template over the manifold there is still misalignment so he had gone back to the drawing board.
Yes and now gone on holiday! In defense he did tell me there would be some delay as he could not get access to the workshop but with all the time in the world with the wrong application and ideas could be in for a long haul. I am giving him the opportunity to fix his mess I guessed I needed to do this but will have to draw the line somewhere eventually. He is now saying he is going to cut the flanges off come round and tack back on in situ and then reweld them back on. With an accurate template (the mls gasket) not sure why he has to come and do that in situ?? If it was me I would be scribing the flanges against the runners in a few places re-drill the channel with 10mm holes, scribe the port onto the channel cut the runners off, line up the flange to the template including the inner scribed lines and the scribes between the flange and the runner. Once in place then port to gasket size. However with the correct application then it must go back to where it was and maybe just need the face milled. However having the car in front of you makes sense as you can then bolt the turbo on (4 bolt exhaust flange), inducer dont think is going to be an issue, however as then in a mobile situation I think be wise to tack it on and then take to workshop rather than weld it on my bin out the front of the house! Guess as well if flanges cut off would then back purging be required or are we beyond that requirement with the state of it.
Tell you what I wish is that I had the required equipment and experience, last time I done anything like this was 3rd year at senior school when I made a toffee hammer on a lathe and brazed the handle on. Ok this is more tricky but if I had the equipment with a bit of knowledge and practice I would have had it back on and the car running. Maybe time to invest and learn, I have good mechanical knowledge and thought process in my opinion just never welded. Yes it wont be pretty but have to start somewhere.
My word. With his level of expertise, I fully expect those split flanges to come back much more warped than they were before, they'll definitely need a skim on a mill that way even with a competent welder.
Cutting them off and re-welding the flanges is NOT a good way to fix that.
Like you say, he has a template - the right way to do it would be to make a bolted pattern into some heavy plate, like 15mm or thicker, and tack/weld it off that, IF the flanges have to come off at all. Still will probably need skimmed, though.
I think you need to sack him off and get someone else on it, someone with better ideas!