Stef's side project

[Stef205]

Ive been wanting to build a manifold for a good while now and to test my self with what im capable to do and to add it to my belt. So my friend that i share a workshop with went out and bought a vnt turbo for his already stage 2 hdi and asked me to make it "fit"
First of i fabricated a mount to sit on the gearbox


Ive since angled the turbo over to have the oil feed level.

Next we got some face plates cut from the water cutters in stainless and ordered a load of mandrel bends.

This is where i am atm with it. 32mm primaries then into a collector to 40mm secondaries is the plan.





No way is it perfect but i hope it will have a good out come, Is as equal as i can get it with good clearance. Im now awaiting on more tube to hopefully finish it all off. All comments welcome

Stef

[Piggy]

nice work fella.

be careful of gear linkages

that a gt2256v/60?

[Ruan]

Audi 2.5 V6 TDi 2052V isn't it?!

Good work! Be interested to see the finished product!

[7057sam]

Wow epic stuff 

 can't wait to see the results

[Matt]

Looks really good mate! Top work!

[Dum-Dum]

Is that the final mounting of the turbo? looks like you have it bolted to the gear box and the gear box mount, one of which moves and one doesn't, you might want to alter that if that's the case.

[welshpug]

the other concern with that location, is melted transmission mounts, though maybe not such a concern on a diesel engine with lower exhaust temps, a gti6 turbo I have heard of had the gearbox basically fall out.

[zx_volcane]

looking good stef!

[Ruan]

the other concern with that location, is melted transmission mounts, though maybe not such a concern on a diesel engine with lower exhaust temps, a gti6 turbo I have heard of had the gearbox basically fall out.

LOL!

Yeah, I'd still be concerned - Diesels will still hit 900-1000*C quite readily under load if given the chance, but off load they're much, much cooler than the equivalent petrol engine - so you tend not to have the issues, but if you're spanking it, you might find the gearbox drops out. Which isn't ideal.

I'd also advise moving the ECU from there - they're pretty hardy, but I somewhat doubt they're a gigantic fan of the temperatures of an exhaust near them.

[Stef205]

Is that the final mounting of the turbo? looks like you have it bolted to the gear box and the gear box mount, one of which moves and one doesn't, you might want to alter that if that's the case.

Well that would be a silly thing to do wouldnt it ive more sence than that and experience.

the other concern with that location, is melted transmission mounts, though maybe not such a concern on a diesel engine with lower exhaust temps, a gti6 turbo I have heard of had the gearbox basically fall out.

Got plans for any heat issues dont worry its all in hand

[Piggy]

Mmm gold foil works wonders

[Poodle]

32mm is going to be a struggle to fit down there, have fun with that! Be interested to watch it come together though, are you tigging it?

[Stef205]

It's been test fitted it fits 32 isn't exactly big primaries anyway used to using 35,38's. So yeah it is fun ! Anyone would think I've not done stuff like this before

[Piggy]

It's been test fitted it fits 32 isn't exactly big primaries anyway used to using 35,38's. So yeah it is fun ! Anyone would think I've not done stuff like this before

I did think this!

All giving their 2pence when your lightyears ahead of us!

[Stef205]

more progress on this today, stainless tube turned up and i started to fab up a collector.





not bad for hand cut with a grinder, the exit will be cut back to match the size of the secondaries.

[Paul Baldwin]

Good effort I take it you're using those 1.2mm INOX disks on the grinder? Amazing difference to those shitty old thick ones you used to get!

[Stef205]

You mean grinding blade hate them with passion! I won't even use grinding blades linisher or flappy pads only

[welshpug]

1.2mm isn't a grinding blade, its a cutting disc.

[Stef205]

I was refuring to the thick "cutting" blades as grinding blades, I only use the thin blades and stainless spec for that matter.

[Paul Baldwin]

I got what you meant. That collector angle is pretty shallow by the looks, should hopefully flow well but makes it an arse to get a weld between the runners!

[Stef205]

I did take a guess with the angles tbh I may change it yet

[Poodle]

Sorry, from the way you wrote the OP it sounds like you haven't done stuff like this before.

[Matt]

That looks like an absolute nightmare to weld! Good luck with that

[Paul Baldwin]

I came to the conclusion that if I did another one I'd cut apart the final version in a few places and weld the pipes individually in the hard to get to spots. Making sure it doesn't warp to $%*! of course.

[Stef205]

I've a plan when it comes to welding it all up.
I have remade the collector as I wasn't happy with it. Just waiting on a pipe delivery to finish it all off.

[Stef205]

im slowly getting the manifold mocked up, ive remade the collector as i wasnt happy with it.





some of it is subject to change as there is a few bits im not quite happy with but more test fitting and observations before the final weld up.

[Stef205]

Thought id update this, A fair bit has been done since the last update. Engine has been pulled to bits as it had suspected head lift.   Head was stripped, skimmed on all surfaces and pressure tested. All new valves, stem seals etc, new victor rein gasket and full arp studs from the states. 


New cambeltkit, water pump and a general paint up of parts. Manifold was wrapped after abit of a tweak.



Turbo refitted, and i started on the downpipe. Excuse my tig work still learning

        



We decided on a second v band as the top half is a real pain (poor design by me) just waiting on the exhaust box

Stef

[Piggy]

Just curious...why did you not clock the hot side a little more to help with manifold fitment/angle?

[Jonny81191]

Any pictures of the manifold before wrapping?

[Stef205]

Just curious...why did you not clock the hot side a little more to help with manifold fitment/angle?

Allowed things to work out better this way, wasnt a issue in mounting and turbo performs as it should.

Any pictures of the manifold before wrapping?

Sadly no, was before i became a tig owner so migged.