Followed all my plans and measurements to a T today and ended up w/ this 5 hours later.

http://imageshack.us>

So what is it?? j/k Looks good, nice work so far. I wish I had the tools/skills to do something like that.

Niccccceeeeeee!!! So when are these bad boys going into mass production? lol

I would like to see the fitment? Are you going to have to remove the fans to fit it in?
-Todd

Originally posted by MitsuEclipseGS
I would like to see the fitment? Are you going to have to remove the fans to fit it in? -Todd

Fitment will be good. It will work for me since I have a Fluidyne radiator and my Slim fans are were the condensor was. I could see it being a problem for ppl w/ stock radiator/fans and AC. The wastegate flange is going to push by the AC but I dont have that so its no worry for me.

I would be more than willing to fit one for someone w/ stock AC and radiator/fans though :)

You have your fans on the front of your radiator in push mode right?? i was thinkin about doin that for more clearance as well. The manifold looks great. Can't wait to see finished product.

Mike, thats not mild steel is it? Is it for mock up or actual useage? Mild steel doesnt support turbo's very well and will crack easily with the heat created by a turbo. Very nice effort.

Terry

Originally posted by Star Turbo Talon
Mike, thats not mild steel is it? Is it for mock up or actual useage? Mild steel doesnt support turbo's very well and will crack easily with the heat created by a turbo. Very nice effort. Terry

No Terry its not mild steel. Its sch10 stainless steel fittings/pipe, it should be plenty strong enough.

I am actually going to be using this manifold right here that I am making. I plan on making another to the exact of this one, but having a local place tig weld it to make it look more cleaner. My welds are okay, but I will be grinding them down so they are smooth with the rest of the pieces to make it look nicer and then it will be powder coated black or silver, not too sure yet which color.

Just an FYI, unless it is a thermal coating from Jethot or HPC, powder will not last.
There are higher heat range powders in the market that work on motorcycle pipes etc, even boat exhausts... but not one will support automotive temps for extended use. (I helped design the turbo headers for Matt Hartford Racing and all were tested prior)

glad to see I was able to contribute to your recent projects Mike!
(sarcasm)

--------------------------------------
know me as santiago
boosted 420a and ej2o..(my 2liter v8 eaters)

Definitely do another one and TIG it. Also, what filler wire are you using for the stainless to stainless... and what about the stainless to mild? You should be using 308 for the stainless and 309 for the stainless to mild. Got any pics of the inside so we can see penetration?

Also, you shouldn't be welding this stuff without cleaning it first. I use a stainless wire brush on a bench grinder and Acetone right before welding... ofcoarse, I TIG mine. You should just buy a TIG welder and learn instead of taking it to a weld shop, where they'll charge you an arm and a leg to weld that up. You can get by with a fairly small welder, I usually only use 70-90 AMPs for sch10 stainless piping.

Pauls right, do not powdercoat it... that will melt. Either ceramic coat it or polish it.

Did you test fit this manifold with your turbo yet? I bet clearance in very tight, if there is any at all.

Nice first effort... manifolds can be a PITA sometimes. :thumbsup

More...?

Hey if you bring that down to my shop in canton, oh i can tig weld that up for you. I have made some manifolds, it quite a fun experience not to mention the ammount you can learn. Looks like you are using some flux-cored wire, correct? It should hold up fine, it just won't look as good as if it was tig welded together. Looks like a good start though, have fun with the wastgate if you have a free float turbine housing, i used a vertial milling machine to cut out the wastegate port after i finished welding up the entire manifold. Oh and one other thing make sure that you get some flat stock material (1/2" works well) and bolt it to the flanges to prevent some warpage, obviously after you weld it up machine the flanges down so they can seal properly. Good Luck!

Originally posted by dougie2
Definitely do another one and TIG it. Also, what filler wire are you using for the stainless to stainless... and what about the stainless to mild? You should be using 308 for the stainless and 309 for the stainless to mild. Got any pics of the inside so we can see penetration? Also, you shouldn't be welding this stuff without cleaning it first. I use a stainless wire brush on a bench grinder and Acetone right before welding... ofcoarse, I TIG mine. You should just buy a TIG welder and learn instead of taking it to a weld shop, where they'll charge you an arm and a leg to weld that up. You can get by with a fairly small welder, I usually only use 70-90 AMPs for sch10 stainless piping. Pauls right, do not powdercoat it... that will melt. Either ceramic coat it or polish it. Did you test fit this manifold with your turbo yet? I bet clearance in very tight, if there is any at all. Nice first effort... manifolds can be a PITA sometimes. :thumbsup

I would love to buy a TIG and learn, but unfortunately thats no where in my budget. Yes it was test fitted first, actually with PVC pipe. That is what I used to make a first mock up actually. I will get some good pics of the inside of the welds this weekend or when I get around to finishing it.

I am getting it ceramic coated, thats what I meant, not powder coated. I decided it will be ceramic coated black on this one.

Originally posted by Star Turbo Talon Mike, thats not mild steel is it?

lol, see the little 304 there? 304, as in 304 stainless.

those welds are scary, and with those metal fits, penetration isnt likely. the bevel will help some though. you need a gap, at least half the metal thickness. are you backpurging it? The weld on the 4th primary at the head flange isnt bad at all.

Like Doug said, you need to use 309 filler when welding mild steel to stainless, always use stainless filler when welding MS to SS. Looks like you used er70s2 or s6 though, in which case its going to rust, and fail.

what size pipe is it, 1.5? the schedule doesnt mean a lot without the size of the pipe.

make sure and make the collector as smooth of a transition as possible, metal fit is everything.

edit...geeze, I cant spell...

Originally posted by turbo8u

Originally posted by Star Turbo Talon Mike, thats not mild steel is it?

lol, see the little 304 there? 304, as in 304 stainless.

Very funny. I didnt even see it ass.

Originally posted by Star Turbo Talon

Originally posted by turbo8u

Originally posted by Star Turbo Talon Mike, thats not mild steel is it?

lol, see the little 304 there? 304, as in 304 stainless.

Very funny. I didnt even see it ass.

lol. Yes it is 1.5 ID pipe.

Im not sure what the wire is, I will have to look at the spool, but it for welding stainless, I know that.

Yea, the #4 runner weld to the manifold come out great. Some are terrible, some are good, lol. They are all getting grided down though :)

edit, practice makes perfect. I just learned how to start welding like 3 weeks ago and should have waited to start this, but i was too pumped up to start it :(

Originally posted by eclipse982nrRST
Yes it is 1.5 ID pipe.

Actually, 1.5" schedule 10 piping does not have a 1.5" ID. It should be 1.682" ID with a 0.109" wall thickness.

Like turby mentioned, the best way to penetrate this stuff is to put a small gap in the butt joint. I usually stick a piece of .035 filler wire in between the two pipes to be welded. It also helps to re-bevel the piping at more of an angle.

Weld penetration is very important with these manifolds.

Looks good Mike!!

looks good mike . try to get a pic of the penetration inside the runners . your never gonna get that one perfect with 3 weeks of practicing tho . a good way to practice is by starting with just flat pieces of steel and do butt joints,t joints and overlaps . by doing that you will find how much gap u need also the most important part is getting ur penetration even

reminds me of when i started my build.

Originally posted by taclipse
reminds me of when i started my build.

You make a manifold?

yes siree

Originally posted by taclipse
yes siree

i seen it. interesting, lol, where are your fans at now on your radiator???

Originally posted by eclipse982nrRST

Originally posted by taclipse yes siree

i seen it. interesting, lol, where are your fans at now on your radiator???

i have a pusher setup.

Originally posted by eclipse982nrRST

Originally posted by taclipse reminds me of when i started my build.

You make a manifold?

Well I know he wanted one at least,lol.

hahahahahahahahaha! nice picture man.

sorry Terry :cheers im just giving you shit

for 3 weeks of BANME! welding, thats not that bad. Like Doug said, penetration is the big thing, not so much what the weld looks like. Especially since you said youre finishing the welds anyway. This is when youll see the lack of penetration, however. If your MIG welding, back hand weld everything, most people forehand weld because they can see better but the weld deposit doesnt penetrate as much.

if you dont know what I mean, instead of welding say right to left with your gun facing like this /, weld with the gun faced like \ this and weld right to left. just a tip, it will help. all structural welding is back hand welded, and theres a reason for that.

let us know what filler is being used, and it also looks like youre using 75/25 instead of pure argon, but whatever.

bravo for building it yourself though, the first one isnt usually the best when youre first starting out but yours is pretty dope.

what turbo you going to hang off that beast?

Looks like a pretty cool project. I wish I had the resources to be able to make a manifold like that. They look pretty cool. Take some more pics of your progress Mike.

Originally posted by turbo8u
hahahahahahahahaha! nice picture man. sorry Terry :cheers im just giving you shit for 3 weeks of BANME! welding, thats not that bad. Like Doug said, penetration is the big thing, not so much what the weld looks like. Especially since you said youre finishing the welds anyway. This is when youll see the lack of penetration, however. If your MIG welding, back hand weld everything, most people forehand weld because they can see better but the weld deposit doesnt penetrate as much. if you dont know what I mean, instead of welding say right to left with your gun facing like this /, weld with the gun faced like \ this and weld right to left. just a tip, it will help. all structural welding is back hand welded, and theres a reason for that. let us know what filler is being used, and it also looks like youre using 75/25 instead of pure argon, but whatever. bravo for building it yourself though, the first one isnt usually the best when youre first starting out but yours is pretty dope. what turbo you going to hang off that beast?

Turby,
That is straight Argon believe it or not. All my penetration's look good actually. I am going to get some more pics of everything this weekend when the collector starts to come together. I do backhand too, it was actually more difficult trying to forehand when I was practicing. I am going to be making another, just in time after I finish this one. Hopefully we could do business together, I could tack these up if some members wanted one, and ship it to you for your MAAD tig skills. We could split $$$, fine with me :)

As for the turbo to be hung by this piece, time will tell :)

Thats part of my 07' Project that will be finishing VERY soon I think :)

If you want to sell them I would be interested in welding/fabricating them with you. Let me know my shop is in canton, we have a mechanical shear, 225ton press break, vertical milling machine, plasma cutter, welders out the wazoo, iron worker, ect you get the idea.

id be more than happy to weld the shit out of those for you

Originally posted by turbo8u
id be more than happy to weld the shit out of those for you

PM sent :)

Do I smell monies...


I already have my season pass, just let me know when to get in line :thumbsup

Originally posted by XMasta19
Do I smell monies... I already have my season pass, just let me know when to get in line :thumbsup

Wahat are monies?

And what line are you getting into? lol.

I am confused, its Saturday and I just got home from work rebuilding a complete 3.8L motor in 6 hours.

Please explain yourself and enlighten me :)

Originally posted by eclipse982nrRST

Originally posted by XMasta19 Do I smell monies... I already have my season pass, just let me know when to get in line :thumbsup

Wahat are monies? And what line are you getting into? lol. I am confused, its Saturday and I just got home from work rebuilding a complete 3.8L motor in 6 hours. Please explain yourself and enlighten me :)

hahah, I probably shouldn't let the beer do my talkin but drunken posting pwns me for sure. Monies is the currency I've been using lately. It's basically imaginary green pieces of paper that I've created in my mind since separating from the Air Force last month and becoming a bum LOL

if you weld stainless, you'll love solarflux! no sugaring

http://www.solarflux.com/

Whats up man, why is it in the market place??

Originally posted by Slo2g
Whats up man, why is it in the market place??

meaning why is it for sale now? because this was my mock up initially and i was going to use but i decided not to mainly because i would like to have a new one tig welded by turby :)

oh, can't wait to see more of what your planning.

Originally posted by Slo2g
oh, can't wait to see more of what your planning.

i would be more than willing to make some of these for you guys, but no one is showing any interest really.

Ill take one get me a price

Originally posted by goalie40
Ill take one get me a price

pm sent

shit you get me pics of a finished product all tigged up ill buy one form you, i need a nice manifold to bolt my gt35r too

amazing looking. I've been wanting a manifold that will spool up a turbo faster. I think that design is great, as both the HRC and Star manifolds actually work against spooling the turbo up faster. How much would you sell one for? A nice ceramic or jethot coating on that and it would be fabulous.

BTW have you all seen the new FP mani?

I have not seen the FP mani yet do you have pictures?

Dirk

This maybe the one he is talking about.
http://www.dsmtuners.com/forums/showthread.php?t=252160