I just wanted to know what i left out of my build other than the stock air bucket.
nothing
Did you do all the fab work yourself?
turbo manifold project
- Thread starter landtank
- Start date
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nothing
Did you do all the fab work yourself?
nothing
Yes
- Thread starter
- #83
update
The manifold is done. I actually inspected it last week before final welding. All flange surfaces have been surface ground and it has been stressed re-leaved.
Since a few people have inquired about a production piece I'm getting some quotes for having it cast. Because of this I won't have it in my hands until after March 3rd some time.
I'll post up detail pics as soon as I can.
The manifold is done. I actually inspected it last week before final welding. All flange surfaces have been surface ground and it has been stressed re-leaved.
Since a few people have inquired about a production piece I'm getting some quotes for having it cast. Because of this I won't have it in my hands until after March 3rd some time.
I'll post up detail pics as soon as I can.
- Thread starter
- #84
One year and two months later the welded manifold is done. It was actually done twice and had a few revisions along the way but I'm real pleased with the final results.
I'll let the pics do the talking
I'll let the pics do the talking
- Thread starter
- #85
2nd set
- Thread starter
- #86
last set
Rick,
I have a naive comment that I just cant keep to myself. What about heat treating the whole manifold? Back when I was an instrument mechanic in the oilfield, heat treatments were performed on welded joints to minimize internal stresses. This is known as annealing where enough heat is applied to the metal to permit the molecules re-orient themselves to lower stress orientations (more crystalline like structures) and thus reduce internal stresses and cracking.
One could argue that the heat cycle offered by the exhaust anneals the metal, but it would be too difficult to keep the whole manifold at the correct temp and the manifold would cool too quickly and trap the molecules high energy orientations (this is know as quenching). A professional shop is really the only way to go. Here is a shop in Boston that does heat treating: Yahoo! Domains Web Card, and another: County Heat Treat - We meet your thermal processing needs.
Kudos to you. I have always found your projects to be inspirational.
Cheers,
Karl
I have a naive comment that I just cant keep to myself. What about heat treating the whole manifold? Back when I was an instrument mechanic in the oilfield, heat treatments were performed on welded joints to minimize internal stresses. This is known as annealing where enough heat is applied to the metal to permit the molecules re-orient themselves to lower stress orientations (more crystalline like structures) and thus reduce internal stresses and cracking.
One could argue that the heat cycle offered by the exhaust anneals the metal, but it would be too difficult to keep the whole manifold at the correct temp and the manifold would cool too quickly and trap the molecules high energy orientations (this is know as quenching). A professional shop is really the only way to go. Here is a shop in Boston that does heat treating: Yahoo! Domains Web Card, and another: County Heat Treat - We meet your thermal processing needs.
Kudos to you. I have always found your projects to be inspirational.
Cheers,
Karl
Nice Rick, whats your plan now?
It looks like it has already seen the inside of a heat treatment oven although I would question any value that a heat treatment would add in this particular case...
About the only heat treatment used on the austenitic stainless steels is going to be done to remove the residual stresses of cold forming or to dissolve precipitated chromium carbides.
As the effects of cold forming are already accounted for in the manufacture of the fittings (they are supplied solution annealed) and chromium carbide precipitation/sensitization should not be a issue for its intended usage so about the only thing a solution anneal is going to do is distort the finished piece.
The most commonly used heat treatment done to remove the effects of cold forming or to dissolve precipitated chromium carbides is going to be a solution anneal conducted in the 1850°F to 2050°F range (1010°C to °C). Cooling from the anneal temperature should be at sufficiently high rates through 1500-800°F (816°C – 427°C) to avoid precipitation of chromium carbides.
- Thread starter
- #93
The manifold did get heat treated but to only stress relieve it. SS 304L only needs to be heated to 700* for 20 minutes I think and stress relieving has been accomplished. The first round of testing was in a self cleaning oven as they can get to 900* and have a nice controlled situation.
My plans, right now I have about 95% of a complete turbo install. I'm missing the hoses tubing and such. I have located and met with a foundry in RI who already cast manifolds out of ductile steel for the BMW crowd with great success. I now need to get a price for making the pattern for the manifold and will hopefully meet with someone this week.
The possibility of a $650.00 manifold exists and when coupled with a T-60 turbo a $2000-$2500 system could be built.
This is as good as anytime I guess, I have been thinking about a "Group Turbo Build". The idea would be for a group of people to share the cost of having these one of a kind parts made to complete a custom turbo kit for the trucks. The obvious pieces would be the manifold-heat shield-bracing, down pipe, intake pipe and intercooler. There would be some other pieces as well I'm sure.
It would be a group effort on design as well. As an example, my turbo location is on the side of the engine behind the right engine mount the tubing from the air filter needs to head down and back. Thanks to a suggestion from Beowulf that has been addressed nicely.
My plans, right now I have about 95% of a complete turbo install. I'm missing the hoses tubing and such. I have located and met with a foundry in RI who already cast manifolds out of ductile steel for the BMW crowd with great success. I now need to get a price for making the pattern for the manifold and will hopefully meet with someone this week.
The possibility of a $650.00 manifold exists and when coupled with a T-60 turbo a $2000-$2500 system could be built.
This is as good as anytime I guess, I have been thinking about a "Group Turbo Build". The idea would be for a group of people to share the cost of having these one of a kind parts made to complete a custom turbo kit for the trucks. The obvious pieces would be the manifold-heat shield-bracing, down pipe, intake pipe and intercooler. There would be some other pieces as well I'm sure.
It would be a group effort on design as well. As an example, my turbo location is on the side of the engine behind the right engine mount the tubing from the air filter needs to head down and back. Thanks to a suggestion from Beowulf that has been addressed nicely.
While you can accomplish a limited stress relief at temperatures of ~450°C (~842°F) and soak times of 30+ minutes cold worked 304 can start to sensitize at temperatures as low as ~370°C (~700°F).
As this material choice has a high resistance to brittle fracture a stress relief PWHT, especially on cold worked (IE cold roll 304 bar stock) or the non low carbon grade of 304 would not be a design & fabrication choice I would make. Instead I would go with 304L material and hot roll bar stock and skip any PWHT.
As you can see there is not alot to do up there in Fort Mac except turn into some metalurgical freakjob 
I am not familiar with Beowulfs suggestion, could enlighten me by telling me where that air can lid came from? I am going to suppose that the plastic thing on top is for noise suppression?
I am not familiar with Beowulfs suggestion, could enlighten me by telling me where that air can lid came from? I am going to suppose that the plastic thing on top is for noise suppression?
- Thread starter
- #96
That filter top came from Japan via MOT. It's off a turbo diesel application. Their turbo is in the same plocation as mine. This way I'm getting the quickest turn out of the filter to where the turbo inlet is. If you look at some of the other build threads you'll see that this can be a mess of tubing to get that done. I've also had a special MAF housing made with a hose connection at both ends. That way a rubber coupling will attach it to the filter cover and another at the other end for the inlet pipe. I'm planning on using that small flared pipe for the inlet to my York compressor at some point.
And that horn is supposed to help air flow by being tuned to the valves in the head.
And that horn is supposed to help air flow by being tuned to the valves in the head.
As you can see there is not alot to do up there in Fort Mac except turn into some metalurgical freakjob
There is a lot to do in Fort Mac; Crack, Meth, Coke, Alcohol and etc. which is why a "freakjob" like me can get away with having the consulting rates I do...
- Thread starter
- #98
update
I just got the quote to make th epattern and I will be having cast manifolds made. I need to draw up the print and then it's about 6-8 weeks out for the first sample to get poured.
I'm damn excited
I just got the quote to make th epattern and I will be having cast manifolds made. I need to draw up the print and then it's about 6-8 weeks out for the first sample to get poured.
I'm damn excited
Way cool! Looking forward to seeing the first production piece.
rick, so what is your company name going to be?
