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Tuning turbo time!

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Tuning turbo time!

dont laugh but heres my progress.

the metal is fecking hard stuff.

gotta get some belts for the air sander which should eat the metal to get the holes the right shape.

somehow managed to drill one stud hole about 3mm to low on the header :(
 

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Munkul said:
Im not laughing... Im thinking "Im glad I'm not craig right now", I hate working with stainless! And so do my drill bits lol
Click to expand...

lol thanks for that. my drill press is not happy after all this. I've actually learnt how to sharpen drill bits and even got them spot on so they don't chip. I also use a syringe full of automatic transmission fluid which helps a lot.
but yeah stainless is nasty stuff but I've saved about £300 by doing it myself so in happy. after all this I'm really looking forword to welding :-D
 
Wow, and I mean wow! I really admire you for persistence and devotion. On the other hand I thought I was the only one that was crazy enough to hand machine my turbo flange, apparently not ;) But mine was mild steel, so probably much easier, and only one flange.
 
I use my drill press as a mill... dont have enough torque for this stainless (works fine with mild steel/cast/alloy)

we also have a die grinder (air and electric) and carbides wont touch is because you cant apply enough pressure to make it cut without causing it to also work harden... once it hardens nothing happens... stones worked better but its all done now... used a air sanding belt thing which had no problem.


started welding it...no pics yet :)
 
thanks :)

the pipes weld VERY easy. but had trouble welding the pipes to the flange where there is limited space to reach the inside of the bend. kept getting leaks, i used about 3 cutting discs griding groves back into the weld to refill. messy is places put leak free and should look better once smoothed out

Ive measured it up as i was doing it and the tubes (inner two and outer two) will be 3mm in length difference! thats as good as i could get to making them equal so would this be classed as equal or does it need to be spot on?
 
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It's probably as close as anyone can get, realistically. But measuring the volume is a more accurate way (dry sand or somesuch).

The volume way is more accurate than trying to measure the length and seems the critical factor. Consider Ducati (who probably make the best stroke engines out there). The later V twins have a silencer under the seat. Obviously the run from the front pot will be longer than the rear one, so they use a smaller o/d pipe to -- more or less -- keep the volumes equal.
 
IMHO... it makes VERY little difference.

You get two opposite schools of thought: equal length, to promote spool-up, and non-equal length... to promote spool-up :D For example, Tomei make equal AND unequal manifolds for the same engines! Power differences are negligible.

There is a school of thought:

Runners from cylinders 1+4 and 2+3 are separated as much as possible with a divider in the turbo flange - this helps minimise any valve bounce problems at high boost and rpm, it also reduces turbo spool compared to some other manifolds.
Click to expand...

Which gives better power and spool on back-to-back dyno tests on the SR20DETs, Ive never heard of the same being applied to other engines though.

The only time it makes a noticeable difference is on a twin-scroll housing with a fully divided manifold, where you want equally timed pulses of gas.

I could be wrong, correct me if I am!

My totally unequal manifold and turbo had FECK ALL lag. Pipe sizing and housing make way more of a difference to spool-up.

BTW... thats a nice looking manifold dude! Keep it up (y)
 
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I see what you mean...

The main reason ive aimed for equal and this design is its something to work from/to (lots of pics to copy online lol) and I paid for the best stainless I could get so might as well have it looking nice and "proper" :p

oh and the 12mm flange has warped slightly! even tho bolted to the head during welding
I dont think ill bother getting it milled flat because it seals ok once bolted onto the head even without a gasket.
 
its cool, you have the satisfaction of telling people "its an equal length manifold" and much kudos from... most people tbh. Me, anyways. It looks like its gonna be a work of art when its finished, and I know how hard it is to weld them feckers...

How are you doing the collector? Preformed, or pipe-chopping?
 
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