Cool project, if you decide to produce the basic "framework" for a kit, I would probably be interested myself.
turbo manifold project (1 Viewer)
- Thread starter landtank
- Start date
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Boyd,
Just looked up my EPC and the air cleaner clamp on the "pipe side" and the "air cleaner side are different. Whether that means the size is different or the same, I have no idea! If you want I can look at my 1HD set-up (not FT/FTE, but "assume" it's gotta be at least somewhat similar).
Not sure if that's what was being asked here, but hope it helps.
Mot
- Thread starter
- #143
MOT, I'll be running a 3" pipe down to the turbo inlet. I had first thought that both ends of that bellows pipe where the same which would be nice to have since the filter side is stationary and the turbo side torques with the motor. But after seeing the drawing I think that there might be a reduction as the factory turbo has a smaller inlet but I'm not sure.
I'm probably missing something significant in the visualization but why not rely on 3" ID silicone sleaves at both ends? The factory turbo apparently chokes down but doesn't yours stay at 3" from airbox to throttlebody? Again, maybe I'm just not seeing something simple here. 
- Thread starter
- #145
If that bellows piece stays at 3" I wanted to use it so it would allow the proper flex in the intake pipe when the engine torqued. That is it's intended purpose. Straight silicone sleeves would be more rigid.
More rigid maybe but they still flex considerably especially if there is a 1/2" or so between the solid tube ends. Anyways, I now get why you wanted that specific thing but unless your motor mounts are failing I don't think yer gonna need more flex than the silicone sleaves can handle. Further, there are silicone sleaves that are ribbed and much more flexible on purpose. Anyway, just in the hope it helps.
Here's a link in the hope it helps. Specifically designed to deal with flex.
http://www.turbohoses.com/Hump.htm
I've just "tried" to get measurement and pics of the part in question.
As you can see the metal pipe going down from the air cleaner box is 7.5cm/3" in diameter (Outer diameter of the hose is 8.5-9cm-ish).
The other end of the hose is slightly smaller with about 7.5cm in outer diameter and the actual metal pipe size (You can kind of see it between the two rectangular text boxes toward the bottom) is about 6.0-6.5 cm-ish.
So it IS indeed smaller.
I was going to take the whole thing off, including the air cleaner box, but was afraid that I wasn't gonna be able to put everything back together. So it was the best guesstimation by using a tape measure.
HTH's!
Mot
As you can see the metal pipe going down from the air cleaner box is 7.5cm/3" in diameter (Outer diameter of the hose is 8.5-9cm-ish).
The other end of the hose is slightly smaller with about 7.5cm in outer diameter and the actual metal pipe size (You can kind of see it between the two rectangular text boxes toward the bottom) is about 6.0-6.5 cm-ish.
So it IS indeed smaller.
I was going to take the whole thing off, including the air cleaner box, but was afraid that I wasn't gonna be able to put everything back together. So it was the best guesstimation by using a tape measure.
HTH's!
Mot
- Thread starter
- #148
Thanks MOT, after seeing the diagram again it looked like it was smaller.
- Thread starter
- #150
I'm tellin ya man, you need some hump hoses.
I'm good with the marital aides thank you!
LOL! I can only imagine the modifications you've made to those!!!
On a serious note, if you'd like some shots of how the Safari uses such stuff, I'll be happy to post them.
Rick
on my FZJ install I found out the the connection to the FZJ air cleaner takes a 3.5 inch Silicone hose, all the other connections are 3 inch. I stretched the 3 inch and made it work, But I just ordered the correct part today! 3" to 3.5" Hump hose reducer... that way you can move it enough to change the air filter.. Here is a link to the part..
eBay Motors: Silicone Hump Reducer Hose Coupler 3.5" to 3.0" black (item 360052808329 end time Sep-12-08 13:00:02 PDT)
good luck and awesome work...
Later Bret
Ps. here is a picture..
Silicone Hose (Hump Reducer)
on my FZJ install I found out the the connection to the FZJ air cleaner takes a 3.5 inch Silicone hose, all the other connections are 3 inch. I stretched the 3 inch and made it work, But I just ordered the correct part today! 3" to 3.5" Hump hose reducer... that way you can move it enough to change the air filter.. Here is a link to the part..
eBay Motors: Silicone Hump Reducer Hose Coupler 3.5" to 3.0" black (item 360052808329 end time Sep-12-08 13:00:02 PDT)
good luck and awesome work...
Later Bret
Ps. here is a picture..
Silicone Hose (Hump Reducer)
- Thread starter
- #154
I talked with the foundry last week and will hopefully have my first two samples by Friday. Right now the foundry is setting up the pattern with the gate system so it produces a consistant casting during the pouring process. this can take a few tries. So they set this up and pour a couple, evaluate, adjust and pour again until they get it right. This is definitely not the time to rush them.
As soon as I get my hands on them I'll post pictures. Then it's off to the machinist to work out that last detail and they should be done, provided they fit of course.
As soon as I get my hands on them I'll post pictures. Then it's off to the machinist to work out that last detail and they should be done, provided they fit of course.
- Thread starter
- #155
As an update, the foundry called today and they seem to have 2 cast manifolds for me to pick up. I'm going to try and get there by this weekend, going to try REAL HARD 
As an update, the foundry called today and they seem to have 2 cast manifolds for me to pick up. I'm going to try and get there by this weekend, going to try REAL HARD
Yoda to Luke (not that I'm Yoda!) : "Don't try, do."
- Thread starter
- #157
Yoda to Luke (not that I'm Yoda!) : "Don't try, do."
Well, two weeks ago I took a sick day on Friday to drive my sons truck home from PA.
Last week I took two personal days to go to our yearly Fall Gathering on Thursday.
My company's good will is pretty much spent right now. Another end of the week day off at the last moment will make them a little testee.
- Thread starter
- #159
I just had a chance to post some pictures. As with anything of this kind of project there has been yet another set back. The hole for the waste gate is out of place and not centered on the casting correctly. If you look at the pictures you will see that the hole is to high and these two casting are never going to be usable.
Not all bad as one of them is at the machine shop so they can program the CNC machine for when the casting are correct. I talked with the machinist and we will be deleting the hole from the core box and machining it into the casting on his end. This will ensure an exact fit and proper sealing of the waste gate.
The bad manifold he has will be machined and then fitted to the engine to make sure everything is correct. I do have another manifold that can be run through his shop if the program needs to be tweked.
Once it has been confirmed that the manifold is correct then a production run will be done. People have asked about the possibility and I'll know more in about 2 weeks when I get the manifold back from the machinist.
If there is interest from others I'll have extras made up in case there is a failure so someone won't be down for any length of time. Being CNC machined they should be close enough that it would be a simple job of swapping one for another.
My next posts will hopefully be a mounted manifold with turbo and waste gate attached.
Not all bad as one of them is at the machine shop so they can program the CNC machine for when the casting are correct. I talked with the machinist and we will be deleting the hole from the core box and machining it into the casting on his end. This will ensure an exact fit and proper sealing of the waste gate.
The bad manifold he has will be machined and then fitted to the engine to make sure everything is correct. I do have another manifold that can be run through his shop if the program needs to be tweked.
Once it has been confirmed that the manifold is correct then a production run will be done. People have asked about the possibility and I'll know more in about 2 weeks when I get the manifold back from the machinist.
If there is interest from others I'll have extras made up in case there is a failure so someone won't be down for any length of time. Being CNC machined they should be close enough that it would be a simple job of swapping one for another.
My next posts will hopefully be a mounted manifold with turbo and waste gate attached.
- Thread starter
- #160
and a few more
