My turbo manifold build thread.

[golf-2000-2l]

Hi everyone.
This build thread is going to be following the progress of my first turbo manifold.

I will be making this out of schedule 40 SS 304, the manifold will be an equal lenght design and will bring the turbo over the transmission (Sidewinder). It probably is a big challenge to accomplish as first time fabricating a manifold.

This thread might be slow moving as school and work take a lot of my time oh and the girlfriend to... hehe but i will try to deliver some good info and I will be open to suggestions,contructive criticism....

Studying in mechanical engineering I guess school is actually usefull now!


Lets move on! Here is a a few info on the car:

Drivetrain:
-6speed 02M quattro
-Audi TT Quattro rear floor
-Haldex...

Engine:
-1.8T 06a block
-calico coated main and rod bearings
-82MM JE Pistons
-ARP head bolts
-IE arp main studs
-IE connecting rods
-IE manual tensionner kit
-IE Arp crank bolt
-IE Dowell pinned crank gear
-AEB ported and polished ( in progress )
-Cat cams 3653
-Supertech valves
-Supertech Springs and retainers
-Precision 5857 journal bearing with ported cover.
-Custom turbo manifold, Sidewinder and equal lenght.
and the list goes on.....

Back to fabrication
STEP 1
Merge collector Jig V1.0


First test cuts and it works flawless!




Its good practice to Tig welding while doing this. Hopefully my skills will improve until I get to weld the actual manifold

What welding technique would you recommend? I was thinking of doing a root pass then a last pass to fill it up (all backpurged). What do you guys think? Any recommendations for a good weld?

Here's a weld on that jig



I will try to get some good pictures tomorow.

[sdezego]

[nubVR]

I think your on the right track..... good luck

[golf-2000-2l]

Thanks guys

Btw Nub your work is amazing!

[nubVR]

Thank you sir

[BARELY LEGAL]

What are you using to cut the collector tubes?

Also, that jig is sweet! Tube just fits inside and gets clamped down?

Watching.

[golf-2000-2l]

I am using a horizontal band saw that I have at work and its working flawless I will post pics of updates later today. I will catch action shots as I cut the tubes.

My welding skills are improving I came across a piece i tig'd a few months ago and it was horrible!

I will make a new Jig eventually (if you noticed the v1.0) but something billet with graduated angles so you can simply choose your merge collector angle and I will also make it so you can make offset cuts to make a more rectangular merge for T3, T4, T25... If the quotes from the machine shops are reasonable I might get a few machined and sell them. But this wont happen anytime soon i have a manifold to finish first!

[golf-2000-2l]

Here are some progress pics people

Here is the band saw in action



Here is how the jig works

Step 1



Then you cut


Step 2

Turn your pipe


Cut it.


Enjoy your work....

[Tougemachine]

Oh my O.O

Looks great

[BARELY LEGAL]

Updates?!

[Maui Stylez]

das pretty badass....

and i spy an A-1000 up there in the background?

[nubVR]

Awesome Jig... never thought of it being that easy! Thanks for sharing

[golf-2000-2l]

Oh my O.O

Looks great

Thanks

Updates?!

Dont have any updates yet, studies are priority even tho making a manifold is a whole lot more fun! Monday I will stay after work to make some progress I will definitly snap some pics.

das pretty badass....

and i spy an A-1000 up there in the background?

Yes it is an A-1000, along with my precision 5857 and the fuel surge tank

Awesome Jig... never thought of it being that easy! Thanks for sharing

Thanks, It is easy but the only thing you have to be carefull with is pipe rotation. You need between 93 and 94 degrees of rotation not 90. The end result will be a true 90 degrees between both cuts and perfect merging. Learned the hard way so I had to cut a second time my pipes on the good side I didnt have to scrap them.

And FYI schedule 80 2 inch pipe is what i used.

My version 2.0 Jig will mount the pipe differently so you simply do a 90 deg to obtain 90 deg. Currently waiting on quotes from a few machine shops .

[golf-2000-2l]

I have updates for the merge collector.

I tried to salvaged my pipe cut at the wrong angle and with sucess it turned out good. But yet still not good enough for me i want perfection so I decided to have a merge collector sitting in my room and I will make a new one but perfect this time!

Who knows the spare one might make its way into my daily driver.

Anyways it is good practice had a trouble welding my weld seem to be a little too hot to my liking i will have to fine tune that before I make the other one.

[BARELY LEGAL]

I like it. Much better welder than I sir.

[golf-2000-2l]

I like it. Much better welder than I sir.

Thank you.
FYI:
www.weldingtipsandtricks.com gives great info on all types of welding. This is pretty much how I learned to weld, I still got some fine tuning to do but I'm on the right track.

[BARELY LEGAL]

Thank you.
FYI:
www.weldingtipsandtricks.com gives great info on all types of welding. This is pretty much how I learned to weld, I still got some fine tuning to do but I'm on the right track.

I've watched some of his videos. Amazing work there!
Really, I just need to get in the garage and weld everyday. Busy with school and work though.
One day my beads will look awesome.

[Filthydubber]

Yup, the welds look a little hot, but the merge collector jig is awesome!

Looking good, I cant wait to see the final product.

[Grahams81]

The merge collector looks great, here's some pictures of mine i have tacked together for inspiration

It's an equal length divided twin scroll sidewinder for a Borg Warner EFR8374 -






I just used some 6mm studding to make a temporary brace to position the flanges correct to each other then built the manifold on the bench on a spare head, once i have it fully welded i will remove the bits of studding and build a proper support mounted from the trans mounting.

fitted -






The length of the pipes is within 0.5" of each other....this was my first manifold i built also, not an easy job getting the pipe lengths the same - i must of redesigned it at least twenty times before i was happy.
I would say i spent at least 40 hrs working on the design of it..... to be honest i'm still not 100% happy - it's very close to the rocker cover so i'm gonna have it ceramic coated and make a heat shield, also gonna rewire coil harness so it comes from other side of the head.

Also what size pipe have you used ????

I started of using 1.5" but found Full Race only use 1.25" on there "response" manifolds (which are apparently good for >800hp) so i switched to 1.25" to aid spool up.

[golf-2000-2l]

Hi Grahams81

thanks for your input, your manifold looks great, I see that there is almost no choizes to get that manifold over to leave clerance for the downpipe to pass under and clear the booster.

As for pipe size I went with 1.5 inch schedule 40, I will see the outcome and maybe experiment with 1.25 if spool up is awfull.

As for updates dont expect anything soon because my finals are coming at a great speed! once those are finished I will jump on this project and get stuff moving real quick!