DIY Tubular T3 Manifold, Top Mount Turbo (PIC HEAVY!) NOW RUNNING

At that level heat flux (Aiflow and EGT) the location and method of merging with the main system may cause a penalty to optimum performance based on packaging issues.
Just somehting to consider in addtion to noise requirements at tracks

 

Performance is main objective and i realise merging it into downpipe will rob power

Think i will make couple of take offs one that vents straight out and also a link into main exhaust when noise is an issue

Take off into exhaust can be blanked off when not in use

 

Today i have fabricated downpipe and mated it to exhaust so i can then decide where to place wastegate and look into options for screemer pipe route





V-Baind added so downpipe can be removed easier with from above engine bay





Couple of tricky offcuts were required to get desired angles













Inserting it into position is easy as its in two pieces









View from under







Placing Wastegate






Just need to make Wastegate screemer pipe and insert flexy joint in downpipe but that will be done once manifold is fully welded

Took it all off and gave manifold to my mate for pro back purged tig welding, cheers Loz!


Once its done i will assemble everything for final trial before final fitting. Will have it tested under full boost and max heat for any potential stress and cracking before i have it wrapped

 

Its coming along nicely Sam.

 

gear cables clear ok Sam?

what size is that turbo... looks like a phat ole hotside to it..

comparison of one which is going into an ibiza here
flexi's on both external gate and main DP


yours is coming along nicely..
great thread!

 

Bill, what was the reasoning behind the wrap on the DP & not coating?

Do you ever use exhaust wrap on top of coating or is that a no go? (Not sure if it would be a case of coating + wrap = even less radiant heat into bay + even hotter, faster flowing exhaust gas...) Maybe manifold just a PITA to wrap?

Sambo - Manifold looks great. How many hours do you think it has it taken to this point?

 

Cheers Bill, yea i made sure i'v left clear route for g.change cables so far, just screemer pipe to make fit yet

Turbo is a GT3082R aka GT3040R with .82 AR hotside and mahoosive compressor, may decide yet to go with GT3076R also with .82 AR hot side for better response

Bill, do you stock any decent heat wrap? If not what make do you use?

 

Cheers, so far around 15 hrs but that is taking my time and measuring everything 3 times!

 

customers budget would'nt stretch to full coating.
I have not ever wrapped a ceramic coated setup as yet.. either or.. but I could see it keeping temps even lower tho

 

I used DEI last time.. from, heatwrapshop.com black stuff. does'nt seem to fray

 

inspirational!!!

i was just wondering did you have the manifold heat treated for stress relief before the coating was applied?

 

nope

 

If the coating could stand up to around 900c or can be redone without breaking the bank, it would benefit from heat treatment. Welding stainless sets up a lot of internal stress because it pulls together, which could cause fractures later.

Acording to azom it would be need to be at 850C for 1 hour to reduce stress by 85%, with rapid cooling.

The downside would be it may need the flanges milling flat.

 

I am gona run my manifold just heat wrapped for a while then i may think about ceramic coating it and wraping it before it goes into final destination, my mk2

 

~Its a question of finances also..
I used Bodycote in my previous engineering life for vacuum brazing and full solution annealing stainless steel (316L) mass flow meters... The full solution annealing with gas quench was over an 6 hour furnace cycle from memory, with very determined temp ramp rate, hold, cool, before quench... The bent tubular flowmeters without being "constrained" would come out a very different shape, but it normalised the welds.. my memories fading on the exact detail but I am pretty sure they held 1042'C as the highest hold temp.

If my customers had the budget for such things I would do it for sure.. We never had a weld failure on these mass meters. (but also not yet ever had a failure of my manifolds either-touches wood)

 

Manifold all welded now, bit of warping but nothing mad. I'l see if i have time to get it blasted before assembly

Pics update this w-end either way

P.s. Seems strong enough to lift engine out with it!

 

Manifold now welded and blasted, looks like ally!









Trial fitted again to make sure all clearances are still ok, all is good









Wastegate got plenty of room, g.change cables got clear route so all its good


Tomorrow i need to finish of screemer pipe, weld in both flexys and thats it, once turbo is plumbed in for oil/water/air i need to wire in new management then i can fire up the bad boy and let you all know how manifold is performing

 

Lookin good, nice wastegate!

 

Nice work Sam what Management are you running now ?

 

Cheers Boys, feels satisfying doing it your self

I'm gona run Nira Motorsport i3+, scandinavian made. Lots of big turbo volvo and saab boys run them up in Sweeden and Norway

Also if its good enough for koenigsegg its good enough for me!