Turbo exhaust mani design

[pork]

I'm gunna make a turbo exhaust mani for the k10, is there any things that I need to consider when designing it? Pipe diameter? Pairing up cylinders? Length?

More info I get the better please, don't really wanna have to make this, but it's got to be done so may as well do it right

Thanks, Neil

 

[Skinner_87]

Matthew on here sent me a good scan about turbo builds Pork, if you pm me an email addess il forward it on if you like

 

[pork]

Sent mate, cheers

 

[Skinner_87]

Sent mate, cheers

No worries on its way to you, hope its some use

 

[frank]

make sure there,s some clearance around the alt neil can you mount it facing forwards on a stock mani like mine ?

 

[pork]

make sure there,s some clearance around the alt neil can you mount it facing forwards on a stock mani like mine ?

View attachment 21178

Haha, for sure!

Il have to have a look, see where it's best placed, jus given my old anifold to engineering from opposite to make up flange

Only get 2 hours a night between work and when the girlfriend comes home to work on the car !

 

[pork]

Can anyone recommend whether short runners or long ones are better, equal lengths matter? Been doing some reading, but haven't come across many testimonials about whether what is best

 

[pollyp]

afew guides to look at

http://www.enginebasics.com/Advanced Engine Tuning/turbo manifold design.html
http://www.enginebasics.com/Advanced Engine Tuning/Short Vs Long Tube Headers.html
http://www.davidenglish.com/swift/Tech/Manifold_Design/manifold_design.html

 

[pork]

Lol, read all of these today

 

[pork]

Another thing, should I be looking at incoperating an external wastegate?

 

[pollyp]

http://www.enginebasics.com/Advanced Engine Tuning/Wastegates.html

 

[frank]

Another thing, should I be looking at incoperating an external wastegate?

pick a big enough turbo, and use the stock exhaust system, and you dont need a wastegate here,s mine with the w/g wired shut and maxing out @ 5psi

 

[pork]

Probably totally impractical, but love the idea of this

 

[pork]

U

 

[pork]

So, got flange made, is this ok, or does it have to be exact shape off the old manifold? I.e with all the little cut out bits?

 

[frank]

you might wanna cut some slits to counter the heat expansion neil, its pretty thick eh !

 

[pork]

It's 12mm, once I've finished welding I'm gunna get the face machined flat, so I've got a couple of mm to work with

Where do you suggest slitting it?

 

[frank]

It's 12mm, once I've finished welding I'm gunna get the face machined flat, so I've got a couple of mm to work with

Where do you suggest slitting it?

its not easy to mount onto a surface grinder as an assembly tbh mate, as long as you weld it while bolted to a head it should stay flat, and here maybe ?

 

[pork]

I've got the old ma10 head laying about so il use that, cheers

 

[Rob]

How much did the flange cost you mate?

 

[pork]

How much did the flange cost you mate?

£50 from engineering bloke opposite. Dunno if that was a good price or not, didn't really shop about, just that he was local and does nice work fast!
Ordered it yesterday evening, done this afternoon

 

[pork]

Trying to make this merge collector right now too

Please take into account, I hav no precision tools whatsoever !!

All done with grinder

Here's progress so far

Now jus gotta splice theses two together

 

[pork]

 

[Rob]

Where did you get the tubes matey?

 

[davey1991]

Very well done with the tools you have!

 

[pork]

Where did you get the tubes matey?

Jus cut this up, 1 1/4 inch steam pipe, went to pipe supplier and asked for a meter and got it for free

 

[pork]

Very well done with the tools you have!

Cheers, trusty grinder!

 

[davey1991]

The single most important tool any man can have closely follwed by the trusty persuader.

 

[Rob]

how are you going to make the bends?

 

[pork]

how are you going to make the bends?

With steam pipe fittings (butt weld fittings)

I've had a go at this today

Been having a quick mock up off things

Please don't take the piss out the tack welds to much, the welder was playing up big time!!!!!

Ran out of regulator broke, then ran out of gas, kept jamming the wire too!!

Bloody cheap crap!

Anyways......

Ran out off fittings now

 

[pork]

Quick test to so if it fits........

..........loads a room!

 

[frank]

can you shut the bonnet tho neil ?

 

[karlj]

**** me that's huge, are you going to get enough exhaust pressure to the turbo?

 

[pork]

can you shut the bonnet tho neil ?

Haha, yup, with a few inches spare'

 

[pork]

#### me that's huge, are you going to get enough exhaust pressure to the turbo?

Yeah, looks a bit big, but honestly doesn't look this massive when its in front of you

 

[karlj]

I'll take your word for it

 

[pork]

I'll take your word for it

Lol

It's 32. Something I.D pipe so matches the exhaust ports, but it's quite thick beings its steel fittings, stainless is a lot thinner.

But these are CHEAP, pipe was free too

 

[Rob]

Thats bloody awesome mate! Hats off to you!

Right... where do i get this steam piping? Im gonna make me a ram horn one! haha

 

[pork]

I got my stuff from a company called BSS, think they are a nationwide company

 

[pork]

Right!

Exhaust mk2

All runners are equal length now with as few bends as possible

Your thoughts please people, because if there isn't anything I'm missing, I'm gunna weld it all properly tomorrow

 

[SirChris]

Thats bloody awesome mate! Hats off to you!

Right... where do i get this steam piping? Im gonna make me a ram horn one! haha

lol I was thinking that!

 

[SirChris]

its good, it seems to have quite equal lengths eh?

 

[pork]

its good, it seems to have quite equal lengths eh?

Yeah, tried my best, there roughly 14inches each

Tried to get as straight as possible too, would like to of gone straight into collector though, but also these loops help avoid the radiator hoses going into engine
I couldn't think off any other way off doing it

 

[SirChris]

where did I read that a long distance between exhust mani and turbo helps stop DET?

 

[pork]

I read the same thing, from engine basics site, apparently helps with that, and helps with being able to have higher compression (from what I've read!)

 

[SirChris]

I read the same thing, from engine basics site, apparently helps with that, and helps with being able to have higher compression (from what I've read!)

I wonder how it improves compression?... waits for Frank to inform us**

 

[pork]

No idea, jus things I've read

 

[SirChris]

No idea, jus things I've read

welll find out! we need to know these things

 

[SirChris]

Do we win a prize for finding the 'where's wally fag butt'?

Right!

Exhaust mk2

All runners are equal length now with as few bends as possible

Your thoughts please people, because if there isn't anything I'm missing, I'm gunna weld it all properly tomorrow

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View attachment 21220

 

[Robbie 733]

Obviously I'm no expert, but ..... there's a Company I came across, that manufactures a Turbo Conversion Kit that is installed by the rear silencer box on an exhaust pipe.
So I don't suppose having the Turbo 14 inches from the Head is too much of a problem ??

Looking good for a DIY jobbie !