Drew's MegaCheap homebrew 3b turbo thread

[amaurer]

1) I resorted to the dremel tool to cut the opening for the turbo flange.

2) ... and then taped everything in place. Btw those nice studs you see in the turbo flange? Tapped those myself. By hand. Not recommended, for heavens sake buy a flange with tapped holes.

3) ... and tacked everything together with my awful 110V FCAW box. I've got access to a MIG welder for the permanent welds but don't let that make you think that I know what I'm doing. My welding experience to date is one 1" bead with the MIG plus one exhaust pipe repair with the FCAW that left me so sun burnt I was popping Ibuprofen like they were Skittles (https://forum.ih8mud.com/40-55-series-tech/400068-welding-exhaust-pipe.html).

 

[amaurer]

Two more.

 

[tmarx]

Suibscribed !

Looking good !

 

[Radd Cruisers]

Judging by all the corks I think your wine consumption during this project is a little out of control there Amaurer, and I'm not even gonna' mention the tub of vaseline that's sitting on the edge of the table.

Project looks good. Simple works just as well as complex in case like this.


~John

 

[slowandsteady BJ]

Judging by all the corks I think your wine consumption during this project is a little out of control there Amaurer, and I'm not even gonna' mention the tub of vaseline that's sitting on the edge of the table.

Project looks good. Simple works just as well as complex in case like this.


~John

Too funny.

Manifold looks great. Keep em' comming (pics....not whatever else is happening in that garage)


Cam

 

[racemaniac]

love this

 

[whats the deal]

Innovative!

 

[FF LC FREAK]

C'mon, don't leave us hanging! You only have 10 more days to get this done and tested! We need closure...

 

[magnus_heydoc]

looks great

I can't help but wonder why you spend 230. on a china turbo when you can get a brand name turbo off a volvo for about 125?
Just my opinion but I got 2 Mitsu turbos off of a 740 Volvo for 250. One's been spinning 14lbs for over 2 years solid and one is an identical spare sitting in my garage.
New is prettier though for better eyeball appeal but my old surf rig is a dirtbag as well as it's owner........Ha!
best
Aaron

 

[VTCDN]

Pictures magnus_heydoc ,, Of yours !!! or it never happened

VT

 

[amaurer]

I can't help but wonder why you spend 230. on a china turbo when you can get a brand name turbo off a volvo for about 125?
Just my opinion but I got 2 Mitsu turbos off of a 740 Volvo for 250.

Step into my time machine, friend, and let me take you all the way back to the first post in this thread:

Granted, the cheapest way to do things would be to do a manifold flip with a junkyard turbo, but I don't like where that puts the turbo and I struck out at the Pick N Pulls near me.

Will have progress to report tomorrow. Parts continue to arrive................

 

[VTCDN]

Good Job, Thanks for posting of all the Info.

I have sent a quote in to Triton Waterjet for a few, with your posted pix and hopefully the correct drawing you posted on the other thread.

I see a few Gents are looking at this item from canada also.

When i get a Quote for a few for me , I will ask for them to be shipped to my Washington house and ill bring them up myself. I KNOW that the Customs guys make everything double plus.

So if your looking for a cut manifold flange , Mr Amaurer has made this part very easy and Nice..

Providing it fits the Head Exhaust Flanged Ports !


VT

 

[amaurer]

Good Job, Thanks for posting of all the Info.

I have sent a quote in to Triton Waterjet for a few, with your posted pix and hopefully the correct drawing you posted on the other thread.

I see a few Gents are looking at this item from canada also.

When i get a Quote for a few for me , I will ask for them to be shipped to my Washington house and ill bring them up myself. I KNOW that the Customs guys make everything double plus.

So if your looking for a cut manifold flange , Mr Amaurer has made this part very easy and Nice..

Providing it fits the Head Exhaust Flanged Ports !


VT

I have a MIG reserved for 4pm this evening to weld this beastie up. If you can wait I'll get it onto the truck this weekend so we can be sure the drawing is correct. If it needs fixing I'll do that too.

 

[canucksafari]

This is a great thread. I might give this a try for my TD4.2 and have two flanges cut by your shop down there. It's pretty hard to beat their time frame and price. My only concern would be warping. Did you ask around about how the mild steel and the thicknesses of the metal or was it a guestimate? My understanding is the cast log ones are so heavy to ensure they can take the heat without warping or cracking.

 

[VTCDN]

I have a MIG reserved

Thats unusual , kinda like rent a hoist ?

Did you not take the cut flange and try it on the Cyl headyet ?

Just to make sure the head studs and bolts fit ?

VT

 

[magnus_heydoc]

I'd better read the fine print..........

Yeah Drew, that is one sentence I overlooked. I guess I got lucky as there are a couple import type mechs. near me and I picked up a mitsu. turbo from a 740 volvo from each
.
VTCDN here's my build FYI:
https://forum.ih8mud.com/diesel-tech-24-volts-systems/298444-turbo-3b-buildup.html

You're gonna love the power. It goes from 90HP to roughly 150HP.
Surf's up so I'm heading for the coast.
Good Luck!

 

[amaurer]

This is a great thread. I might give this a try for my TD4.2 and have two flanges cut by your shop down there. It's pretty hard to beat their time frame and price. My only concern would be warping. Did you ask around about how the mild steel and the thicknesses of the metal or was it a guestimate? My understanding is the cast log ones are so heavy to ensure they can take the heat without warping or cracking.

The short answer is that I did not do a lot of analysis about the thicknesses. Its a guess, primarily, based on some info on the web I found that said ".125 is a good thickness for turbo manifolds".

The longer answer is that my hands are kinda tied. I can't use tube larger than 2" without blocking access to the studs. I also can't use anything thicker than .125" or I'll reduce the size of the holes I can cut and then need to grind/cut/mill extensively to cover the 3B exhaust ports. If you were willing to do the extra work you could easily make 1/4" wall work, but I was trying to keep it simple.

Anyway, its an experiment, I'll let you know how/if it holds up. I can say that its impressively heavy already.

I have a MIG reserved

Thats unusual , kinda like rent a hoist ?

Did you not take the cut flange and try it on the Cyl headyet ?

Just to make sure the head studs and bolts fit ?

VT

Its a machine shop that you can "join" for a monthly fee. When you need equipment you just call and reserve a 4-hour block of time with that machine so that some yahoo isn't there welding some bull**** "sculpture" when you need to get real work done.

Anyway, no, I haven't tested the flange yet. The truck is my DD, and the move means that the garage is full of packed boxes and my boat, so I haven't had time to pull the manifold. The boat is moving this weekend tho, so the truck can go in and I can do the swap.

A new exhaust gasket lays perfectly on it, however.

 

[VTCDN]

""" some yahoo isn't there welding some bull**** "sculpture" when you need to get real work done.

A new exhaust gasket lays perfectly on it, however.

2 FUNNY.

I just got a e-mail back from M @ Triton ""[FONT='PrimaSans BT,Verdana,sans-serif']I think we just did that last week, so it shouldn't be too tough to make more. The one in the picture was 1/2" thk mild steel, but we can make it out of whatever you want... stainless, aluminum, plywood... whatever you prefer.""

[/FONT][FONT='PrimaSans BT,Verdana,sans-serif'][/FONT][FONT='PrimaSans BT,Verdana,sans-serif']Plywood !! Ok-Doky..

I will wait before i put in an order , just to make sure the bolt pattern is correct. If you used a exhaust manifold gasket for the template , I'm thinking that is alot of trust on the gasket manufacture . Since i have a few spare / test stuff here I'll go check.

Mr [/FONT]magnus_heydoc , kewl & thanks for the link.

A few shots of stuff

VT

 

[amaurer]

I will wait before i put in an order , just to make sure the bolt pattern is correct. If you used a exhaust manifold gasket for the template , I'm thinking that is alot of trust on the gasket manufacture . Since i have a few spare / test stuff here I'll go check.

Oooh, puttin the pressure on me now! I'll post up this weekend how it fits, or I'll fix the drawing if need be. Stay tuned.

I just spoke to Mark @ Triton to pay my invoice - turns out he just bought a cruiser: I'm thinking this hobby needs more people with their own waterjet shops!

 

[VTCDN]

Well i just put the exhaust gasket on the removed manifold and it's dang close to exact .
I'll post a pix of it.
Was going to weld the cast Volvo flange to the stock 3B exhaust manifold just to see.

VT