Divided T4/Twin WG Turbo Manifold+More!(updated 3/26/17)

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Alonso
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Divided T4/Twin WG Turbo Manifold+More!(updated 3/26/17)

Post by Alonso » Tue Apr 05, 2011 9:11 pm

For being the guy that suggested this subforum to klattr1, I sure don't post much in here Lol.

Here's my latest little project. Decided to try out a divided turbo setup,so now I need a new manifold...

Here are the flanges(purchased from bmcrace.com) and the collector pieces. I cut the pipe with a chop saw, 17* cut and a little eyeballing haha.
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The pipe is 304L stainless steel, 1.5" schedule10.

After some fit up work and deburring. Then the halves were tacked together. The flange isn't tacked tho.
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That's my progress so far as of today.

Pic from this past weekend. Trying to figure out how I'm gonna squeeze everything in there lol
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Last edited by Alonso on Sun Mar 26, 2017 7:13 am, edited 4 times in total.
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Post by TinyT » Wed Apr 06, 2011 7:30 am

should be pretty nice! Out of curiosity, what welder are you using, what does your pack purge setup consist of, and whats your torch setup for stainless? I just like hearing what other people do for stainless.
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Post by Alonso » Wed Apr 06, 2011 9:06 pm

I welded the halves today. Here's one of the welds
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I used ER347 .045 dia filler rod.

Tiny I have a miller synchrowave 250 with 2 regulators in my booth. One is for purging, and it has its own shut off valve. I use a watercooled 20 series torch with a gas lens and a #12 cup most of the time. I run scotchbrite inside the cup.
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Post by franman » Wed Apr 06, 2011 9:47 pm

Welds look great, looking forward to seeing the end product.

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Post by beercandrifter » Thu Apr 07, 2011 5:40 am

what are you going to do for the wastegate setup, running 2 wastegates?
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Post by airman » Thu Apr 07, 2011 9:44 am

Gorgeous welds, keep it up

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Post by TinyT » Thu Apr 07, 2011 11:07 am

Whats your torch angle like when you come around that corner in the last pic? Are you pulsing at all or just dabbing? looks great.
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Post by Alonso » Thu Apr 07, 2011 5:33 pm

Yea 2 TiAL MVR 44mm wg's. I'll be ordering them this weekend.

I clamped the pieces so they were straight up. Started in the middle and went about 1/2". Then turned it around and did the same thing for the other side. Laid it flat then finished the bead. No crazy torch angle was needed.

What you can't see is how THICK the weld is where the pieces are at an acute angle. Although it looks small, it's as thick, if not thicker, than the pipe wall itself...

I don't pulse at all, and didn't really dab either. More like shoved the rod in. LOTS of it. Some of the ripples pictured I fed about 2" of rod at a time. Yea I burned through a few sticks fairly quick just on these halves alone haha.

Keep'em coming T.
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Post by sdaigle240 » Thu Apr 07, 2011 5:43 pm

wow! beautiful! i hope the **** talking loosers in this thread feel like jack asses

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Post by smbonn2005 » Thu Apr 07, 2011 5:57 pm

Damn that weld looks amazing! Great work dude

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Post by Alonso » Thu Apr 07, 2011 5:57 pm

I forgot about that thread lol. Thanks for defending me tho!

I wish I could take pics of what my shop does on a daily basis. The whole website would be drooling lol. They really are the best group of welders I have ever worked with!
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Post by TinyT » Thu Apr 07, 2011 6:12 pm

Alonso wrote:
Keep'em coming T.
alright last ones :D

ballpark number of amps? and how fast were you traveling? Stainless is a bi*ch for me, I can weld cast aluminum in my sleep, I just havent been able to get ahold of stainless pipe welding. Pipe to 1/2" head flange? sure, all day. but these damn pipe butt joints just dont look right! I can make them strong, but I cant get my puddle to stay uniform, sometimes it looks like its trying to slide downhill. The welds have color and Im not overheating it, its just in how I move the torch and how I add the filler.

sorry for asking all these questions in your thread
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Post by Alonso » Thu Apr 07, 2011 7:01 pm

Not a problem man.

I move fairly slow, watching the edges of the puddle making sure its stable and not trying to go all over the place yet it it flows smoothly into the base material. I feed plenty of rod, I can see the puddle kinda building up then it starts dropping down. When I see it going down that's when I add more filler and,so on and son. Sometimes I stop and go. Stop, add rod, go as the puddle drops, stop add rod etc etc...

Try to do smooooooth motions, like you're making love to the metal lol. Patience, don't rush it.

Ill see if I get a chance to do a butt weld for you tomorrow.

Do you have any pics of some your ss butt welds?[/url]
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Post by TinyT » Thu Apr 07, 2011 7:18 pm

I will take some pictures tomorrow after work. I just went out in the shop and did some practice lap welds on some 316 to make myself happy lol

I like to think I have a handle on the metal, meaning Im aware of what the puddle is doing and how my bead is looking behind the cup as I move, and how my movements are affecting things. But for some reason my 304ss but welds dont work well.

We'll get this handled :D
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Post by Alonso » Thu Apr 07, 2011 8:08 pm

Hey tiny, what's your torch setup? Gaslens?
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Post by TinyT » Thu Apr 07, 2011 9:24 pm

for stainless- 17 torch, large gas lens, #12 cup, 3/32 red.
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Post by Alonso » Fri Apr 08, 2011 12:27 pm

Do you run anything in your cup? Screen or scotchbrite?
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Post by TinyT » Fri Apr 08, 2011 2:45 pm

just the screen that comes on the lens. I get awesome stainless welds on plate lap joints, T's, pipe to plate, but I just cant get the nice bead that the high level fabricators do on pipe butt joints. Im just holding myself to a higher standard, I can make strong welds, Im just after the appearance that guys like Toxic Fab and Agtronic can do.
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Post by ALTKAT96 » Fri Apr 08, 2011 2:50 pm

Looking good man!! I think I'm gonna open up a thread on one I'm making for my fwd KA..

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Post by erich » Fri Apr 08, 2011 5:16 pm

Nice welds. I wish my hands were that steady.

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Post by Alonso » Fri Apr 08, 2011 8:02 pm

Thanks for the compliments everyone.

Tiny believe it or not, your setup like that is not enough. You need something inside that cup to act as a diffuser. I suggest running scotchbrite, the white/light duty stuff is what we use.

Cut yourself a piece that fits snug inside the cup. Loosen your tungsten(preferrably a contaminated piece) and push it in to make room for the scotchbrite. Now put the piece inside the cup, flush with the end. Then let the tungsten rest on the backside of the pad or slightly pushing on. Don't bother trying to poke a hole, as soon as you strike an arc it'll burn a perfect hole.

Swap in a clean electrode, set your gas flow anywhere from 25-45cfh and give it a whirl.
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Post by Alonso » Sat Apr 09, 2011 11:52 am

Butt weld from earlier today. 321 SS .040 to .085 thicknesses...
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Penetration
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Only one start/stop point. 8.25" dia...
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Post by El_Cangri » Sun Apr 10, 2011 5:58 am

Wow! Best welds I've ever seen!

Makes me want to learn welding lol! (I was going to but $$$$$ for classes meh..)

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Post by Alonso » Mon Apr 11, 2011 6:36 pm

This my progress so far. I promise to post higher quality pics soon (crappy droid 1 phone)

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All that's left is to seal it from the inside, some clean up and hit the flange a bit to make sure it's flat. Then I'm ready to move on.
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Post by Alonso » Tue Apr 12, 2011 6:48 pm

Nicer pics finally!
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It's alotta pics I know. I'm not gonna post only the best looking welds, I'm not perfect lol.

Also doing the fillet weld around the halves to flange kinda sucked, as I only had .045dia 309L filler to use. I tried to do it per D17.1 specs, which states a fillet weld must be 1.5 times the thinnest member. In this case the pipe is .105 wall, spec calls for .1575, I got it close enough lol
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Post by Inferno s14 » Wed Apr 13, 2011 11:18 am

its never alot of pics..good work man.

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Post by Alonso » Thu Apr 14, 2011 7:05 pm

The WG flanges came in today. These were in the box as well

Twin MVRs!
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Support the US economy :wink:
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Post by Alonso » Fri Apr 15, 2011 8:46 pm

Collector is done. Now I can move on to the next step...
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Post by turbo2nr » Tue Apr 19, 2011 6:37 am

sick work man!
if you can weld you can make anything..

deff. jealous lol
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Post by adamky » Tue Apr 19, 2011 8:41 am

That looks fantastic so far. Nice welding work.
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