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

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DC47A
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Post by DC47A » Mon Mar 05, 2012 11:34 am

Very well done! Not many people know how to properly work with aluminum and this is spot on! This thing is never gonna crack or leak no matter what you put it through!

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Alonso
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Post by Alonso » Mon Mar 05, 2012 7:28 pm

Thanks!

The last thing I want to worry about at the track is a busted end tank!

The end tank came back from heat treat this morning then went to chem clean. Here it is in all its T6 glory :D

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The tube with the ferrule on the end will be shortened to length tomorrow, then welded to the tank. After that the end tank will finally be welded to the core!
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DC47A
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Post by DC47A » Mon Mar 05, 2012 8:32 pm

You did not have to anneal it before you worked it correct? Like the design to, its gonna flow sweet in and out of that core.

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Alonso
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Post by Alonso » Tue Mar 06, 2012 9:55 pm

Didn't do anything to it prior to working with the material. It was soft enough that the 2 large radiuses were "rolled" with my hands at home on the kitchen floor lol.

Quick mock up before i weld the end tank to the core for good...
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Post by adamky » Wed Mar 07, 2012 7:48 am

Nice progress. That end tank is badass.
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DC47A
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Post by DC47A » Wed Mar 07, 2012 7:55 am

End Tanks look great in car man! So BIG

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Alonso
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Post by Alonso » Sat Mar 24, 2012 11:53 am

Put in work this morning. Made the end plates and tacked them.
Hopefully by the end of next week it'll be fully welded and ready for heat treat/age.
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This one has a 3.5in outlet. Also the clamp set came in earlier this week.

Here's the billet 90mm tb from ebay with the 3.5in clamp set sitting on top...I'm tempted to just fillet weld one of the ferrules to the opening and eliminate all silicone couplers in the system. Well, except for the intake.
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TanManS14
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Post by TanManS14 » Sun Mar 25, 2012 1:33 pm

I ordered two of those ebay TB's. One for my car and i put one on Silvk's car. The first one leaked like crazy, the second one leaked just a little bit at first, but im told its gotten worse now.

I've heard you can get new seals for it. I might just try and disassemble it and see if i can lathe out some metal ones or something idk. Id be curious to see if yours leaked. maybe i just got a bad batch, because all of the reviews i had heard were good and being used on some high hp cars.
It's always broken.

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Alonso
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Post by Alonso » Mon Mar 26, 2012 2:05 pm

Ive considered dumping it for a q45 tb, and its not surprising to hear about them leaking. I figured id give it shot anyways since it was fairly cheap...

When it first came in, I disassembled it for the hell of it. Tore it down to just the bare housing and the shaft... The shaft is pressed into the bearings which are the sealed type i believe? Im wondering if there's even a seal under them...that was as far as I went as i didn't have a way to press out the shaft.

Also how can the bearing be removed? It doesnt look like they can be pressed out...one way I can think is by destroying them..
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TanManS14
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Post by TanManS14 » Mon Mar 26, 2012 3:43 pm

Went through the same debate with the Q45 TB. I like the simplicity of the ebay Tb, and having the option to weld it.

Im not sure as i haven't disassembled mine. I think a lot of the talon guys run them but have yet to find anything conclusive on dsm forums about seals etc. I just messaged the seller i got it from, asked for any support on dis assembly/ diagrams they can give me or places to purchase legit seals. Prolly a blind alley.

It sucks though, because id rather have the design of the 100 dollar ebay TB than some 300 dollar hypertune that id feel like **** welding to a manifold/ worried about frying.
It's always broken.

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Alonso
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Post by Alonso » Tue Apr 03, 2012 7:41 pm

Got this done today. Also sealed the inside.
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It was done on a turntable/positioner

I've decided Im gonna take my chances with the ebay tb...

Also the other end tank came back from heat treat/chem clean today. I welded a ferrule to it but did a terrible job,I'm still kicking myself for rushing it :x most likely the weld will be ground out and redone...
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TanManS14
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Post by TanManS14 » Wed Apr 04, 2012 12:10 pm

Def a sick weld. Why did you choose to weld it inside and out? Didnt get any response from the distributor of course lol. Im sure even if it is bad you'll be able to figure something out.
It's always broken.

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Alonso
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Post by Alonso » Fri Apr 06, 2012 6:42 pm

I've seen somewhere that these are copies of the old Veilside tb's?

It's not surprising you didnt get a response back about replacement parts...

As for welding the inside, extra insurance i guess lol. Just feels more "complete".
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Post by 808KA » Sat Apr 07, 2012 1:38 pm

Amazing welds.
Do it!

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TanManS14
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Post by TanManS14 » Fri Apr 27, 2012 4:11 pm

Were the runners on the exhaust manifold done in a single pass? Tried out the scotch brite today lol, couldn't quite get the results i wanted. Very difficult to keep her cool and keep it wide and not undercut.
It's always broken.

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Alonso
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Post by Alonso » Fri Apr 27, 2012 4:46 pm

They were done in 2 passes, backpurged both times.

What was your gas flow set to?
Do you shove a bit of rod in at a time or do you just lightly dab?
What dia was the filler you were using?
Were you backpurging?
What size cup were you using?
Got any pics of the weld?


Need more input lol.
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TanManS14
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Post by TanManS14 » Fri Apr 27, 2012 9:12 pm

Yea, just didnt want to thread jack. But since you asked lol. I was just wondering if you did it in one pass.
http://i177.photobucket.com/albums/w206 ... fe723f.jpg Torch.

http://i177.photobucket.com/albums/w206 ... b56f11.jpg
One on the left i got about the correct size bevel. One on the right was wayyy too big. I did 6 or 7 more pipe welds just didnt photograph em. They got a lil better puddle wise and filling the bevel, but theyre still too hot and or gas coverage problem.
http://i177.photobucket.com/albums/w206 ... 046ad4.jpg

Both the passes in the picture were of 25cfm. .045 filler, #12 cup with scotch brite.
In my other passes i changed flow higher and lower, changed to standard #8 gas lense and collet (which i couldnt tell the difference), and tried .035, .045, and 1/16 filler. I like .035 because its really smooth and dosnt disturb the track of the puddle. But i cant fill the bevel without either moving slower or dabbing so hard that the puddle wanders. I tried both quick small dabs and shoving it in their as i dab and just couldn't get it to really fill the bevel without putting entirely too much heat. .045 is the perfect median. But they still just look hot and like they have poor gas coverage.
It's always broken.

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Alonso
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Post by Alonso » Fri Apr 27, 2012 9:30 pm

They look fine to me and completely acceptable. Only rejectable weld is the one that turned gray inside.

Do you think they're too hot because of the blue color? I've seen much worse pass xray...

Also i always ran 35cfh.

Have you ever read/looked at a weld spec? I try to go by the AWS D17.1 weld spefication when welding my own stuff.

Also when purging remember argon is heavier than air/oxygen. Try purging from the lowest point and locate your vent at the highest point.

Sux that I cant run some beads for ya in person :(
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Post by TanManS14 » Fri Apr 27, 2012 10:06 pm

Ahhhh, my purge was kind of inconsistent, and i knew there had to be a way to fix it. Thanks for the tip on the vent, that should help a LOT! I do think i tried kicking up the gas flow, but i dont think to that extent. I'll give it a try and see what she does at that cfm.

Nope, never looked at actual specs for an acceptable weld before. *****, me too man. The main fabricator at the shop i do bi*ch work for isnt a very good welder. He fabricates well, cages n stuff. Which is great to learn from. But id love to watch someone experienced lay down a few passes. Seems like a damn efficient way to expedite the learning curve.

And yea, i always assumed blueish purple was hot.
It's always broken.

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Alonso
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Post by Alonso » Tue May 22, 2012 7:32 pm

Alright where were we...

Ah, the intercooler is 100% done finally. The outlet is 3.5in.
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The plate welded to the bottom would help(I think) direct some airflow to the radiator and is used for mounting also. It sits nice and solid :D
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Finally starting making progress on the intake manifold also
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Tomorrow the plate will get tacked to the runners so I can check to see if the hood still closes!

Lastly, snapped this while messing with the car
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Yeah buddy 8)
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Post by sdaigle240 » Wed May 23, 2012 7:00 am

those end tanks are amazing! as is eveything else as always.
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Post by Daily Driven 240 » Wed May 23, 2012 7:49 am

Holly ****!!! Great work and those welds are amazing.

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Alonso
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Post by Alonso » Wed May 23, 2012 9:18 pm

Thanks guys!

Tacked the plate and checked to see if the hood still closes...
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...and it sure does with room to spare. Too bad the hood is all hacked and mangled, I think an unmolested oem hood should clear without any issues.

While messing with the car, my lovely wife put this one together using instagram!
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:D
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Post by MRLuke » Fri May 25, 2012 5:50 am

Alonso wrote:Alright where were we...

Ah, the intercooler is 100% done finally. The outlet is 3.5in.
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The plate welded to the bottom would help(I think) direct some airflow to the radiator and is used for mounting also. It sits nice and solid :D
Image

Finally starting making progress on the intake manifold also
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Tomorrow the plate will get tacked to the runners so I can check to see if the hood still closes!

Lastly, snapped this while messing with the car
Image

Yeah buddy 8)
Post is full of awesome :) :o
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sdaigle240
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Post by sdaigle240 » Fri May 25, 2012 6:20 am

eye seks!!!!!!!!!!!!!!!

cant.stop.looking.at.end.tanks.


everything!

is that a ka-t girl in training? shes all about that new intake mani!
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Post by Alonso » Mon Jun 04, 2012 9:27 pm

She's definitely a fast learner! At the rate I'm going, I'll have my own pit crew soon lol.

Finally got the plate fully welded to the runners
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I know the welds inside are fugly, they will be ground down to a radius eventually

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I really like the finish on runner#1. It was done with scotchbrite pad(previously polished) and would be super easy to touch up if needed.

Also got some much needed dimensions and will start designing the plenum...
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Post by Super Coupe » Mon Jun 04, 2012 10:27 pm

Looking good. Love the stock pile of intake manis in one of your pictures.
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Post by Walperstyle » Mon Jun 11, 2012 5:33 pm

I want to quit my job and just hang out in your garage. Is that ok?
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Post by Alonso » Mon Jul 02, 2012 6:25 pm

Walperstyle wrote:I want to quit my job and just hang out in your garage. Is that ok?
You'd get bored, not much going on there lately!
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Post by Alonso » Mon Jul 02, 2012 6:32 pm

Finally! More progress!

Hand done radiused inlets
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Tomorrow I'll start cutting material to fab the plenum!
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