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Thread: Forced Induction Section Fabrication Thread

  1. #101
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  2. #102
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    rehosted













    Last edited by black bnr32; 10-13-2012 at 05:24 PM.

  3. #103
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    heres a few more honda manifolds i made for my drag car and my friends drag car.

    first edition


    used the same collector jig i posted a few pages back...



    then i modified it for the next season because i ditched water to air and went back to air to air intercooling.



    heres one my friend darin and i fabbed up for his drag car.








    and then this top mount we fabbed up one day for fun






    thats the best part about mild steel, its so cheap you can make crazy stuff like this, and they never crack! never had a manifold crack yet.

  4. #104
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    Quote Originally Posted by black bnr32 View Post
    rehosted
    Pretty much BADA$$ -

    wow

    and though the WG are not in our engineer's "preferred" location,
    the system DOES what it's designed to do.




    Quote Originally Posted by black bnr32 View Post
    rehosted







    Last edited by milKt; 10-13-2012 at 07:57 PM.


  5. #105
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    Tanks95 is offline M3s Only Have Two Doors BMW CCA Member
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    nice thread.

    If your M3 doesn’t have 3 pedals and 2 doors, I would really consider contacting BMW to confirm the authenticity of your incorrectly badged mid-sized family sedan.

  6. #106
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    I'm not entirely sure how the gates are tied into the manifold, but it sure looks unique.

    And notice the slip joint connecting the gate and downpipe
    Last edited by black bnr32; 10-13-2012 at 07:24 PM.

  7. #107
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    Some unique setups in this thread.

    It's time for some tig action. To get that nice color that everyone oohs and aahs about you need to clean the surfaces to remove any oil residue that can contaminate the weld.I grind the finish of the metal then use alcohol and wipe everything.



    An auto tinting helmet is a nice thing to have, welding cap and gloves.



    #5 gas cup.



    Settings on the machine, 55amps, no pulsing and around 5 seconds post flow.


    I weld all the pipes but leave the collectors tacked and the flange tacked.



    My manifolds powering 8sec and over 1000rwp cars
    Home of the highest HP stock M30 in the world 550rwhp/622rwtq
    1/4 mile---> 9.81 @138 C4 Auto
    10.08 in car vid --->https://youtu.be/OiinFhUomjg
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  8. #108
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    Amazing thread! I have a few questions regarding some fabrication, welders and such...just too lazy to type from my iPhone....

    Will ask from a pc lol

  9. #109
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    Otis, great info yet again. For those of us who are learning, its nice to know settings and such used by others.

    That RB manifold is definitely interesting. Would be cool to get some better pictures of the collector to see how the wastegates work. I would also be curious to know how much better that WG tie in to the downpipe is than say a typical angled connection? Seems like a ton of effort, but I don't know if the gains are significant enough to warrant it. Either way, cool stuff.

    I am interested to see the F1 manifolds for 2014 and how they make the collector and all that. I have seen some early pics of the McLaren engine with semi finished exhaust and it had two 3-1 collectors into secondaries (V6 engine) and the secondaries ended without connecting. Obviously not wanting to spill the beans too much. I have read that the teams are allowed a single turbo and they are allowed their own aero for turbine and exhaust so I am curious to see what the turbine housings look like. Not sure if they are allowed internal WG or not of if that option would even be on the table if it is allowed.
    -Nick
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    Turbo Camshaft Thread

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    Never use Brake clean to clean parts prior to welding because it turns into phosgene gas.

    Sent from my GTX3582R
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  11. #111
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    I spent some time reading that thread. Its very interesting, in a good way. Not going to go into details here because its a fab thread, but the WG does not exit 90deg from the collector necessarily. Each runner has a port that exits into a chamber where the exhaust gas is extracted from.

    the video should show more detail. Also the other videos/thread explains more.
    [ame]http://www.youtube.com/watch?v=0FI9D861Hd4&feature=relmfu[/ame]

    Thanks for pointing out the thread! The performance benefit per $ is not there for a broke azz person like myself, but I love the concepts and detail.
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

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    ^
    So the RB collector IS designed VERY IDEALLY.


  13. #113
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    Quote Originally Posted by good & tight View Post
    A nice gas lens would help you get some better color, and also a lot better gas coverage. Also, beveling the joints and getting better fit-up before welding would produce a much stronger and more cosmetically appealing weld.

    PS: That design looks familiar....

    Last edited by ar design; 10-14-2012 at 11:28 AM.
    ar design stage 1 turbo kit - 11.7 @ 127mph 12psi of boost..... 5300ft elevation E36 S50 stock long block w/ARP

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  14. #114
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    Quote Originally Posted by wazzu70 View Post
    .
    I must have missed that video when reading that thread, thanks for posting. You are correct about the wastegate design. I just can't imagine hand forming that downpipe tie-in. IIRC, there was some difficulty in the heating/forming/cooling process. the mani and collector are 321 ss and the downpipe is 304

  15. #115
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    would this be an appropriate thread to also talk about fabrication tools or a different thread?

    i am interested in learning to weld and would like to know what would be a good tig welder to start with, what kind of tungsten is needed for sch40 and so on, also all the features of the welder as well.

    or just get the info of some welders forum

  16. #116
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    Do you have a budget in mind? Do you want to do aluminum as well?
    ar design stage 1 turbo kit - 11.7 @ 127mph 12psi of boost..... 5300ft elevation E36 S50 stock long block w/ARP

    sales@ardesign.info | tel. 303.351.3515| www.ardesign.info
    Powering some of the world's fastest BMWs

  17. #117
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    Quote Originally Posted by 1980corvette View Post
    would this be an appropriate thread to also talk about fabrication tools or a different thread?

    i am interested in learning to weld and would like to know what would be a good tig welder to start with, what kind of tungsten is needed for sch40 and so on, also all the features of the welder as well.

    or just get the info of some welders forum
    The first discussion you need to engage is what materials you'll be using. If steel, there are a bunch of decent DC only TIGs. If aluminum you'll need an AC/DC TIG. Stuff like tungsten and such is just one of those preference things. What does matter about tungsten is what type of machine you end up with whether inverter or transformer - there are certain tungsten types that do and do not work well on inverters (ceriated is pretty much a good choice for both DC and AC work on an inverter) and there are also different styles of grinding for inverter vs transformer - ie., for aluminum on an inverter you'll grind to a point while on a transformer you'll want to ball the end.

    Schedule 40 pipe is pretty gnarly stuff not many people use that for anything on cars.


  18. #118
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    Quote Originally Posted by milKt View Post
    ^
    So the RB collector IS designed VERY IDEALLY.
    Correct! He also looks like a wizard which is a bonus. Maybe GG knows him?
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  19. #119
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    That WG recirc is NUTS.
    ar design stage 1 turbo kit - 11.7 @ 127mph 12psi of boost..... 5300ft elevation E36 S50 stock long block w/ARP

    sales@ardesign.info | tel. 303.351.3515| www.ardesign.info
    Powering some of the world's fastest BMWs

  20. #120
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    If you have a chinese welder that is DOA, 99% of the time it is a loose connector inside the machine.

    Pulse tig makes welding aluminium easy. It can also make your welds look a lot nicer cosmetically when welding stainless or mild steel.

  21. #121
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    Quote Originally Posted by ar design View Post
    A nice gas lens would help you get some better color, and also a lot better gas coverage. Also, beveling the joints and getting better fit-up before welding would produce a much stronger and more cosmetically appealing weld.

    PS: That design looks familiar....
    I've tried the gas lens, it's to bulky to get in some areas. The water cooled torches are more compact and have smaller tips.
    And correct on the familiar design.




    Since the exhaust port is oval I mark the pipe and squeeze it in the vise to match, so there is a smooth transition.
    Before



    After


    Next up is to secure the head flange on a thick piece of steel and tack or bolt it down to keep it from warping. I also grind off the steel coating around the ports to clean metal. Clean all your welding joints with alcohol again.



    For welding to the flange I use a size 6 cup and turn the amp's up to 100.
    You want to keep the tip more on the flange since it's thicker to get good penetration, if not you end up burning through the pipe.



    My manifolds powering 8sec and over 1000rwp cars
    Home of the highest HP stock M30 in the world 550rwhp/622rwtq
    1/4 mile---> 9.81 @138 C4 Auto
    10.08 in car vid --->https://youtu.be/OiinFhUomjg
    Dyno vid... http://www.youtube.com/watch?v=C7aM7..._order&list=UL

  22. #122
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    Quote Originally Posted by ar design View Post
    A nice gas lens would help you get some better color, and also a lot better gas coverage. Also, beveling the joints and getting better fit-up before welding would produce a much stronger and more cosmetically appealing weld.

    PS: That design looks familiar....

    It sure does

  23. #123
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    Quote Originally Posted by GG///M3 View Post
    It sure does
    Correct
    My manifolds powering 8sec and over 1000rwp cars
    Home of the highest HP stock M30 in the world 550rwhp/622rwtq
    1/4 mile---> 9.81 @138 C4 Auto
    10.08 in car vid --->https://youtu.be/OiinFhUomjg
    Dyno vid... http://www.youtube.com/watch?v=C7aM7..._order&list=UL

  24. #124
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    Quote Originally Posted by wazzu70 View Post
    Correct! He also looks like a wizard which is a bonus. Maybe GG knows him?
    We all know the wizards of PA and GA.
    They are very helpful gents to have solid contacts with.


  25. #125
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    Quote Originally Posted by good & tight View Post
    Correct


    Stealing manifold designs from vendors, and making threats to send their designs to China is real classy of you... You have been selling manifolds using this site for years while vendors pay to do the same thing. I wonder how that works? Care to explain?

    http://forums.bimmerforums.com/forum...&postcount=183
    Last edited by GG///M3; 10-14-2012 at 03:11 PM.

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