Exhaust Manifold - Update#4
Turbo Mini Forums

Axel - looking good - I think the gasflow is going to be pretty good out of there without dividers.

good job

JK

If Carling made Mini engines
it would probably be like this one!

axel, great job there the angle into the collector is prety much the same as mine and i didnt use any dividers . Are you aiming to fit this without firewall mods?

anway keep the pictures coming its looking great :)

1152cc turboed mini clubman, most powerful 1.1L a-series?

http://boostmini.justboard.net/

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Getting there:



Just need to weld the branches on, but I need to get some Solarflux or set up a back purge.

So far I've been able to clean up the inside of the weld, but I will not be able to with the remainder.

The welding is not brilliant, but not bad for my first attempt at TIG. The important thing is the the internal surfaces are clean and smooth.

Edited by Paul S on 20th May, 2007.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Mirage-dude, make your EVO2 manifolds like this one with the banana-outer pipes! PLease :)

better strong than pretty axel ,good for you !

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

being tig welded you can take away some of the weld without making it weak if the weld pentration is good, i gorund the welds and then used a flappy wheel to give it a nice finish, although cant really be seen from engine bay.

1152cc turboed mini clubman, most powerful 1.1L a-series?

http://boostmini.justboard.net/

I used an 8mm solid carbide end mill.

Took ages, going in about 0.5mm at a time, cut two slots on each side, then turned the work through 90 degrees and did it again.

Next time, I'd use my plasma cutter and finish it off with the die grinder, that's what I've done on the inlet manifold.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Its looking good, are you going to mill the turbo flange flat again after you have finished welding, it looks like it has "pulled" slightly where you have welded it, although that may just be the picture?

No, you are right, the welding has pulled the flanges banana shaped, but the central area around the ports is still reasonably flat.

Once all the welding is finished I'll dress the flanges up with a grinder. Too much setting up to try and mill it.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Bummer, although remember that as you pull the turbo studs up it will tend to pull the edges to the turbo flange and may well seal OK??

Nearly finished. Bit of weld dressing to do.

Took a while as in the end I set up a back purge for the final two welds. That Solarflux was £60 a tin!



I've just checked the head flanges and the maximum size feeler I can get in anywhere is 0.005", so I think the gasket will seal OK. Turbo flange does need a bit of work.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Decided to mill the flanges:

Used a 10mm end mill on the turbo flange



Tried a fly cutter on the other. Blunted the cutter, but did the job.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Fairplay...doing well there Axel! :)

Edit: Still trying to get to grips with inventor 3d......damn program!

Edited by Jason G on 16th Jun, 2007.

really appreciate the pics axel , its great to see it taking shape .

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

It just occured to me Axel,

What turbo is going onto this? I was under the impression for some reason that it was a GT17, dunno where I got that from.

Anyway I got mine glued together last night, I put the pics up here if thats ok, make it easier for people searching.

As you can see I have a round hole in the turbo flange to suit the GT17 I have or a GT25v

Thats looking good.

Mine is for a T2, hence the square hole.

The next one will be for the GT17.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Ah, righto.

would it be easier/better to whip the ex housing off the GT17 an "square it out"? getting a decent join with 3 pipe into 1 hole is a real PITA.


Jesus, my garage is a tip!!

I honestly do not think that it is a good idea to meddle with the turbine housing, although I know Robert has done what you suggest successfully.

There is no reason to open up the ports at this point because the turbine housing has already started to speed the flow to drive the turbine.

I dont think that it is any easier to get the three pipes to fit a rectangular hole.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

mmm,

I was wondering where the A/R taper actually started from, I was asuming as long as it was done before the internal wastegate vent it'd be ok.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Axel,

Did you have any issues with the manifold shrinking when it cooled down?

I googled the themal expansion of 304 and cam up with approx 20nM per metre at around 500deg, (sod all)

trouble is after cooling i seem to have lost about 1/4" over the whole length of the manifold...

No, I didn't.

I made the centre and end sections, cutting and welding as I went. So if there was going to be any shrinkage, it would only be due to one weld.

Is your shrinkage due to bending?

I always weld around the pipe in 4 goes, always starting 180 degrees from the last hot spot. This minimises the bending at the weld joint.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Good advice axel.

Every day is a school day ...........

How fast and how expensive ...... the same question...