Inspire by Dusty's Turbo project, here is my own turbo manifold.
Was originally plan to do the equal length turbulence style manifold, but end up doing log style manifold due to many stupid reason. Anway, the safari style turbo kit use log manifold as well, so i guess this will work.
The manifold was done by local exhaust shop. I use 48.3mm diameter 304 3mm thick stainless steel weld ell. You may already notice that i have the vertical support on top of manifold between flange plate and pipe. further more, i had a support beam between turbo turbine housing and engine stand. These are to ensure that my manifold won't fall apart or crack when i am doing extreme off-road ride. I am going for the 5000km off-road rally race at May, hopefully, the manifold will be strong enough to last.
The cover with handle bar on the turbine was there so i can drive it home and complete the rest of turbo. I thought it is a good idea too, in case if the turbo break in the middle of road, i can put this cover back in and continue to drive in N.A. form.
The turbo came with internal wastegate, but only open at 15psi or more, definitely too much for me, i remove it and lock the hole and replace with Tial style 38mm external wastegate. This one is made in Taiwan, much better in quality than Chinese made one i bought before.
Here is a view with compressor attached. I use the diesel turbo. Holset HX35w. commonly use on the 5.9 cummins diesel engine. It will spool up fast enough and sure support up to 400~500hp with good tune. The exhaust has nice polish machine, i spend a little time to polish the compressor housing...not too bad. Holset has a big factory in China, and their products where widely available here. I paid like 230USD for this brand new turbo.
The exhaust shop has little experience of making turbo manifold. The T-pipe isn't long enough, and need to be extend. Under my request, they weld both inside and outside to ensure this thing won't crack.
The stainless beams are there just to position everything correctly.
finally put everything together and weld them with TIG welder.
No matter how good you jig the flange, it bend slightly after weld together. Well, in China, we have a really simple way to fix this, a big hammer and a skill worker solve this problem.
and sander bed is also require just to make sure everything is flat
Here is another view of a new made manifold. The O2 sensor hole is there for the wideband O2 gauge.
The shop also made me the rest of exhaust pipe and the intercooler and intake pipe, so i don't have bother too much with these rubber couper. It takes total 12 hours a day and 3 working day to complete everything which make me really tire at end...... i was there whole time to watch and help.
Tony
Was originally plan to do the equal length turbulence style manifold, but end up doing log style manifold due to many stupid reason. Anway, the safari style turbo kit use log manifold as well, so i guess this will work.
The manifold was done by local exhaust shop. I use 48.3mm diameter 304 3mm thick stainless steel weld ell. You may already notice that i have the vertical support on top of manifold between flange plate and pipe. further more, i had a support beam between turbo turbine housing and engine stand. These are to ensure that my manifold won't fall apart or crack when i am doing extreme off-road ride. I am going for the 5000km off-road rally race at May, hopefully, the manifold will be strong enough to last.
The cover with handle bar on the turbine was there so i can drive it home and complete the rest of turbo. I thought it is a good idea too, in case if the turbo break in the middle of road, i can put this cover back in and continue to drive in N.A. form.
The turbo came with internal wastegate, but only open at 15psi or more, definitely too much for me, i remove it and lock the hole and replace with Tial style 38mm external wastegate. This one is made in Taiwan, much better in quality than Chinese made one i bought before.
Here is a view with compressor attached. I use the diesel turbo. Holset HX35w. commonly use on the 5.9 cummins diesel engine. It will spool up fast enough and sure support up to 400~500hp with good tune. The exhaust has nice polish machine, i spend a little time to polish the compressor housing...not too bad. Holset has a big factory in China, and their products where widely available here. I paid like 230USD for this brand new turbo.
The exhaust shop has little experience of making turbo manifold. The T-pipe isn't long enough, and need to be extend. Under my request, they weld both inside and outside to ensure this thing won't crack.
The stainless beams are there just to position everything correctly.
finally put everything together and weld them with TIG welder.
No matter how good you jig the flange, it bend slightly after weld together. Well, in China, we have a really simple way to fix this, a big hammer and a skill worker solve this problem.
and sander bed is also require just to make sure everything is flat
Here is another view of a new made manifold. The O2 sensor hole is there for the wideband O2 gauge.
The shop also made me the rest of exhaust pipe and the intercooler and intake pipe, so i don't have bother too much with these rubber couper. It takes total 12 hours a day and 3 working day to complete everything which make me really tire at end...... i was there whole time to watch and help.
Tony
