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Post by 0ta220 on Dec 28, 2013 20:54:15 GMT 10
getting started on the intake manifold and new exhaust =) all the mandrel bends and flanges from ecs engines in SA who have great prices and are very helpful to make the velocity stacks i just made up a steel die on the lathe and pressed it into the ally tube. luckily it was seamless and had been annealed
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Post by 0ta220 on Dec 28, 2013 20:58:33 GMT 10
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Post by 0ta220 on Dec 28, 2013 21:09:13 GMT 10
had to check that itd actually fit then learnt to weld aluminium....... bare in mind that this is the first ally work that id done so the welds arent that good but with some grinding they came up alright =) i did weld inside and out just to be safe
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Post by 0ta220 on Dec 28, 2013 21:12:04 GMT 10
should be a little better than the stock one anyway! this is about as far as ive gotten with the intake as i got sick of ally and moved onto the exhaust side
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Post by ta22hp on Dec 28, 2013 21:32:10 GMT 10
wow you have some skills on you
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Post by 0ta220 on Dec 29, 2013 20:18:25 GMT 10
ok so the next thing to do was a new turbo manifold thanks to the old cast one cracking the old ct26 turbo was completely screwed so i thought id rebuild it; i bought all the parts to rebuild it including a a new compressor wheel and then forgot that the thread on the shaft is left hand so i twisted the shaft as i was pulling it apart so that was the end of that! i then bought a gt28 off gumtree, turns out it was one of the twin turbos off a skyline =( so that was too small! i got sick of buying crap turbos and finally spent some real coin and bought a gt2860rs =D
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Post by 0ta220 on Dec 29, 2013 20:25:11 GMT 10
the new manifold is mild steel and consists of 12mm laser cut flanges and 3.8mm walled 1.5inch pipe i didnt bother tyring to make it equal length, just so that it would flow reasonably well the external wastegate is fed from the centre of the merge collector
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Post by 0ta220 on Dec 29, 2013 20:28:43 GMT 10
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Post by 0ta220 on Dec 29, 2013 20:29:46 GMT 10
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Post by 0ta220 on Dec 29, 2013 20:30:31 GMT 10
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Post by 0ta220 on Dec 29, 2013 20:35:43 GMT 10
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Post by 0ta220 on Dec 29, 2013 20:38:38 GMT 10
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Post by 0ta220 on Dec 29, 2013 20:46:27 GMT 10
so this is what i learnt to tig weld on at uni and now i hate going back to mig so i had to buy a new welder haha AC/DC 170amp weld master (found one second hand and it is amazing!) anyway; the merge collector was welded inside and out so that i could shape it all with a die grinder for nice smooth transitions
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Post by evanta22 on Dec 30, 2013 16:54:59 GMT 10
This is awesome work mate saved yourself thousand.
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