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Thread: Forced Induction Section Fabrication Thread

  1. #1576
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    At least the 2nd go around welding this cast went a ton better. I don't know if it was all just the settings on the machine or some of that and mostly the throttle body being dirty metal. But either way the nipple I welded on for the IAC is just fine.

    IMG_20170316_173629990.jpg IMG_20170316_185254816_HDR.jpg IMG_20170316_185847848_HDR.jpg IMG_20170316_220519198.jpg IMG_20170316_220532533.jpg
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  2. #1577
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    I had a real fight welding the elbow on my throttle body. It seamed like the casting was full of air pockets and oil


    86 325es, 2.8L m50, S476sxe, ProEFI 128 ecu, e85, solid rear axle, TH400 trans, 28x10.5w slicks, zip ties, popsicle sticks, tape
    best time 9.06 @ 151.8 mph, best 60 foot 1.30

  3. #1578
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    Quote Originally Posted by someguy2800 View Post
    I had a real fight welding the elbow on my throttle body. It seamed like the casting was full of air pockets and oil
    That's what it was doing for me as, I'm just gonna assume it was the metal then lol.
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  4. #1579
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    It could be pure luck, but I've had very good results in this regard since I have become less tentative when welding these castings. Let the cleaning action make a nice shiney spot, then pour the heat to it and start pushing filler rod. Working very nicely for me, even when I'm a lazy bastard and don't clean up the casting as well as I could/should.

    - - - Updated - - -

    someBODY (as oppose to someGUY), that weld looks perfectly fine and workable, but still a little cold and tentative to me. I think you can have better results if you get after it harder once you see the clean shiny metal pop up.

  5. #1580
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    That's the trick with many metals that are known to be a pain. People fight discoloration on stainless and think lower amps will help. When in fact, jamming more than you need and moving faster is better. Same with aluminum, it soaks heat like a sponge so if you pussyfoot around you will make a huge mess and be chasing your tail. But if you go in hot and heavy and roll out immediately as you start the bead, it'll suddenly seem easy.

  6. #1581
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    Yeah the biggest change that helped me on aluminum was more heat. Use a bigger gas lense, twice the heat, all the frequency. Be ready to go for it though.


    Sent from my iPhone using Tapatalk
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    2004 Built motor TiAg/Black - Sold
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    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  7. #1582
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    Why use a bigger lense for aluminum?

  8. #1583
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    Quote Originally Posted by cj.surr View Post
    Why use a bigger lense for aluminum?
    Cleaning
    1996 332IS
    Built 3.2
    CES/Steed TS Precision 6466, spraying a "$π!℅" load of meth.
    Technique Tuning 80# tune.
    1/4 mile 10.84 @ 136.72
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  9. #1584
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    I've found a bigger lens is only good for stainless and titanium where you can never have too much argon - it's also a waste if you don't need it as if you don't jack the CFH you will get worse coverage. I also find that the bead gets wider with a larger cup. So for alu I'd get only as big a cup as you need. YMMV

  10. #1585
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    I've kind of settled on a -8 gas lens cup for just about everything. What do you guys like?


    86 325es, 2.8L m50, S476sxe, ProEFI 128 ecu, e85, solid rear axle, TH400 trans, 28x10.5w slicks, zip ties, popsicle sticks, tape
    best time 9.06 @ 151.8 mph, best 60 foot 1.30

  11. #1586
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    I use about a #6 on my small gas lens setup for my CK9flex torch at about 10cfh. I'm too lazy to change it, and I'm too cheap to use more argon. I suppose I could have prettier welds on steel with better coverage, but I guess I don't give a f*ck about that haha.

    As far as for aluminum, it works fine this way for me, and one of the best aluminum welders on the internet - Roy Crumrine - seems to use a #5 regular (non-gas-lens) cup for his aluminum work.

  12. #1587
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    Seems like i have been using stubby 5-8 depending.

    Any of you guys use "Morse" 811 blades ? I just grabbed a 3pk and a roll of Lee rap around.
    Last edited by Butters Stoch; 03-17-2017 at 02:52 PM.
    1996 332IS
    Built 3.2
    CES/Steed TS Precision 6466, spraying a "$π!℅" load of meth.
    Technique Tuning 80# tune.
    1/4 mile 10.84 @ 136.72
    Your 1 and only stop for all your BMW performance needs
    WWW.CESMOTORSPORT.COM

  13. #1588
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    I use stubby lenses with various cup sizes, 5-7 being common. I think the 6 is usually on. I have a Fupa 12 for stainless and a Weldtec Megaflo for titanium and stainless. Only drawback is lenses require more gas. Stubbies need 15cfh, the big ones 25-30. For big volume work, normal diffusers work fine and use less gas.

  14. #1589
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    Quote Originally Posted by tptrsn View Post
    It could be pure luck, but I've had very good results in this regard since I have become less tentative when welding these castings. Let the cleaning action make a nice shiney spot, then pour the heat to it and start pushing filler rod. Working very nicely for me, even when I'm a lazy bastard and don't clean up the casting as well as I could/should.

    - - - Updated - - -

    someBODY (as oppose to someGUY), that weld looks perfectly fine and workable, but still a little cold and tentative to me. I think you can have better results if you get after it harder once you see the clean shiny metal pop up.
    Yep, jumping in and welding like you're paid by the inch of weld is the way to go with TIG. Dorking around with it at low heat just makes things much harder. Sometimes I bust out my best beads when I'm just trying to finish something up real quick.

  15. #1590
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    I hear you! Most of my most perfect little stacks of dimes happen by accident, and it pisses me right off haha...

  16. #1591
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    Friend had an intercooler with a large crack all the way down one side. Played around and got it it fixed up for him. What I learned is that just because a TIG 200 can do 200 amps doesn't mean you're gonna enjoy it haha. That torch sure gets hot at just 150 amps!!!
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  17. #1592
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    I will never go back to aircooled. My torch is the size of a 9 and I can weld at 200 amps all day and hold the torch head bare handed if I wanted to, let alone the handle.

  18. #1593
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    Quote Originally Posted by TheJuggernaut View Post
    I will never go back to aircooled. My torch is the size of a 9 and I can weld at 200 amps all day and hold the torch head bare handed if I wanted to, let alone the handle.
    For what I use it for it's going to be fine but if I had a cheap water cooling option I'd take it.
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  19. #1594
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    Yep i use a -8 gas lense for almost everything.

    Some pictures from this weekend with my -8






    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  20. #1595
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    I think I'm going to buy this

    http://www. harborfreight.com/horizontal-vertical-metal-cutting-bandsaw-93762.html

    My buddy said he used to use one a lot for building roll cages and stuff on the side. Figure if it can be half decently reliable doing that it'll be fine for the projects I need it on. Hopefully will make cutting the intercooler piping and exhaust a lot easier. $198 with the 20% coupon.
    Last edited by somebody5788; 03-20-2017 at 03:49 PM.
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  21. #1596
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    Quote Originally Posted by somebody5788 View Post
    I think I'm going to buy this

    http://www.harborfreight.com/horizon...saw-93762.html

    My buddy said he used to use one a lot for building roll cages and stuff on the side. Figure if it can be half decently reliable doing that it'll be fine for the projects I need it on. Hopefully will make cutting the intercooler piping and exhaust a lot easier. $198 with the 20% coupon.
    I have inspected them and looked into reviews on them. The speed is way off for metal, and they are not very rigid supposedly. Food for thought.

    I have been looking for an old grob in the 500$ range..


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  22. #1597
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    Quote Originally Posted by vollosso View Post
    I have inspected them and looked into reviews on them. The speed is way off for metal, and they are not very rigid supposedly. Food for thought.

    I have been looking for an old grob in the 500$ range..


    Sent from my iPhone using Tapatalk
    80 fpm is too fast? It has 3 speeds 80 to 200 fpm
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  23. #1598
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    I just bought a swag V4 , Milwaukee deep cut with miter attachment. High quality. Works awesome.

    As for the HF , I'm unsure the quality. I think buying Lenox blades would be the best thing you can do for it.
    1996 332IS
    Built 3.2
    CES/Steed TS Precision 6466, spraying a "$π!℅" load of meth.
    Technique Tuning 80# tune.
    1/4 mile 10.84 @ 136.72
    Your 1 and only stop for all your BMW performance needs
    WWW.CESMOTORSPORT.COM

  24. #1599
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    Quote Originally Posted by Butters Stoch View Post
    I just bought a swag V4 , Milwaukee deep cut with miter attachment. High quality. Works awesome.

    As for the HF , I'm unsure the quality. I think buying Lenox blades would be the best thing you can do for it.
    I've got 1 friend with first hand experience and lots of youtube video reviews. It sounds like with proper initial setup and changing the gearbox oil right away that it's not that bad.
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  25. #1600
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    Quote Originally Posted by somebody5788 View Post
    80 fpm is too fast? It has 3 speeds 80 to 200 fpm
    I've been using one of the China bandsaws like that for something like 25 or 30 years, and from what I can tell they aren't bad. My complaint would be that the blade speed seems a bit low for what I usually want, so I rarely use that sucker since I got my drycut and then even less after I got my HF portaband. I'd get that DeWalt DW328 and a swag or homemade table for it instead.

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