this is for a college project, to complete my nc in engineering. i have to do a project. i was thinking for my nexia i could make a turbo compatible manifold.
only problem is, where do i start? my lecturer said it will be a good project, i have very limited knowledge of sheet metal and welding, and have never done any metal forming or casting.
is it possible to diy? what processes would i use to make it, and how could i go about it?
cheers again
Pete

well i guess you would get a bit of tube and bend the tube.
want to see how bad mine went?
it dont matter if you dont finish it tho
for me most of the marks was in the design and the final presentation
oh i did a btech in mechanical engineering lvl3

The Unknown said:

well i guess you would get a bit of tube and bend the tube.
want to see how bad mine went?
it dont matter if you dont finish it tho

Click to expand...

wouldn't you have to attach the bits on that attaches to the intake and turbo and block etc? that must be welding?
did you try it then? what tubing did you use? yeah lol lets see how it went lol.
i dont think it matters if i finish practical, aslong as i do paperwork, and make a start on it.
thats what im doin, a btec national level 3 in engineering.

i didnt do that i tried to make a car lift

well im guessing looking at mine 4 tubes forming into one thats just trig and simple plasma cutting after bending

im guessing its just a tube going off into a turbo

oh sorry, when u said wanna see how bad mine went i thought you'd attempted it to.
yeah thatd be trig i guess, i dont know how to plasma cut, id have to see if i could talk nicely to plasma cut lecturer here. i though it had a flat head on the end, the sort of head that a gasket goes on. perhaps it doesnt then.

well you will need to cut holes into it and holes for the ends of the pipes to match up
plasma cutting is easy but tricky to do complex shapes
oxyaxetaline might be usfull
and genrall a drilled hole using a whole saw can get a good effect.
im guessing your college will have a milling machine that makes things easier. to get angles
welding is easy if its just mig welding the entire thing

for assembly it might be ebst to say your going to make a jig / fixture
to align everything for you
keeps things square to block for bolting on then hopfully.

i could eb compleatly wrong in the infomation tho

ok cheers, il have a look into it. yeah my col has milling machines welders the lot. iv never mig welded, but iv tig welded so will just do that.
however, for the turbo end, id probably need a turbo at hand to measure up the piping for that end, i wont be able to afford that for a while

tig thats even better.

maybe even do it in stainless

may be good to design it to a set pressure. so you can test it with water if you do finish it.

yeah stainless, then i could say i have a stainless system haha.
i wouldnt know how to design it to a set pressure, what pressures does air travel through the intake?

no idea. turbo may say on the box.
i dont know if its wise to do
place a pressure gauge on end of exhaust and rev and note the max then apply a SF

or you could calculate it by the fact you know the in pressure. explosive potential energy and the release. i think we was taught the fundamentals of this

il research for this cheers
whats sf?
what units did you do then? iv not learnt anything like this yet, closest to this iv learnt is mechanical principles which was calculating forces in different directions etc etc.

safety factor

we did fluid mechanics and such i think it was in thermodynamics.
doubt i could work it out anyways tho

i have never done this sort of thing before im just offering advice.
i am a fabricator tho. and have tested cooled sealed equipment before (with water)

the testing should be simple aslong as its low pressure.
plug ends up (hopfully you will make some plates) add water into one end and pump. or use a compressor which may be more apporopriate

its about time we did that, we dont cover that though, instead we do maths, further maths, cad, comms, business and a few more. most of them we done last year, and this year is last few modules. did u go higher with hnc or degree or something? what do yo do then?

we did
plc (programmable logic controllers)
fluids behavior and properties
pneumatic and hydraulic control
further maths
cnc
maths
project
mechanics
materials
electrical and electronic principles
cad
engineering drawing
thermodynamics
further mechanics
communications for technicians
business systems
and some others maybe


now im at uni doing structural Eng with arch studies

What exactly is it you are aiming to achieve?

Are you just attemting to copy the original or come up with an improved version ?

There is a lot more to manifold design and efficiency than tacking a few offcuts of random diameter 304 stainless tube or similar together.

Suggest you read up on the basics of Volumetric Efficiency and the effect that manifold design has on it

No doubt Munkul will be on to add his knowledge he made his own manifold to Turbo his 1.2 16v Mk2 Punto :slayer:

https://www.fiatforum.com/members-motors/223834-mk2-sporting-turbo.html

sledge said:

What exactly is it you are aiming to achieve?

Are you just attemting to copy the original or come up with an improved version ?

There is a lot more to manifold design and efficiency than tacking a few offcuts of random diameter 304 stainless tube or similar together.

Suggest you read up on the basics of Volumetric Efficiency and the effect that manifold design has on it

Click to expand...

no at the moment it is just a normal manifold. however, i am hoping to fit a turbo to it, so im sure that would require a new manifold. so in essence i would be making an improved version.
cheers for the tips

ChrisUK said:

No doubt Munkul will be on to add his knowledge he made his own manifold to Turbo his 1.2 16v Mk2 Punto :slayer:

https://www.fiatforum.com/members-motors/223834-mk2-sporting-turbo.html

Click to expand...

cheers, il wait see if he comments, if not il pm him