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

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(manifolds, chassis, personal projects, MIG, TIG, etc)
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eazye2000
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Post by eazye2000 » Wed Jun 22, 2011 7:32 pm

Alonso wrote:Sorry its a one-off, for my own personal abuse only :twisted:
....abuse, or personal satisfaction? lol
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Alonso
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Post by Alonso » Wed Jun 22, 2011 8:29 pm

Well, both lol.
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Post by Alonso » Wed Jun 29, 2011 5:22 pm

The last runner was finally welded to the collector!
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Welding the last runner to the collector was a bit tough! Still managed to achieve 100% penetration though!
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I have some 3/4" 6061 AL plate that's gonna get drilled and tapped so the head flange can be bolted down before welding the runners. That's on the to-do list along with punching a couple of holes in the collector for the wastegates.

I'm so ready to move on to other ****! Lol
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Post by Jackasknissan » Thu Jun 30, 2011 12:47 am


I'm so ready to move on to other ****! Lol
i know the feeling....

i envy your seat time and experience for tig, how long have you been doing this?

looks solid

imo i would consider going heavier for your plate to stop the flng from warping

ive seen some stainless flanges pull pretty bad on marine stuff.

beautiful cratsmanship none the less
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Alonso
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Post by Alonso » Fri Jul 01, 2011 8:38 pm

I've been doing tig for roughly 3-3.5yrs? That includes school. It would've been longer if it wasn't for the **** economy :roll:

The flanges are hot rold steel. They won't pull as much as SS, but I've seen how bad they can get if welded without being bolted down lol...
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Post by PinkNinja » Sat Jul 02, 2011 11:04 am

If you can. Just torque it to a KA head. SS can warp pretty gnarly if it's not welded correctly.

Mild steel can still warp just as bad. Just allow for lots of cooling time.

I feel your pain with the economy. I've been welding 8-9 years. Went to college for welding 3-4 years ago. Graduated 2 months before the recession.
Now I'm so sick of it I'm back in school doing something completely unrelated to the industry.

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Post by TinyT » Sat Jul 02, 2011 3:47 pm

Lol @ welders pointing out the blatantly obvious to each other. Oh head flanges can warp when you weld them? get outta here! you crazy.

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Post by PinkNinja » Sat Jul 02, 2011 6:49 pm

^oh look. You're a dick on here just like HT.

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Post by eazye2000 » Sat Jul 02, 2011 7:40 pm

PinkNinja wrote:^oh look. You're a dick on here just like HT.
Um, yeah.... But he's OUR dick...

And damn you Tiny for cheating on us on other forums. I thought you were only a dick here? lol

/threadjack

This thing is killer. I would like to sell my Full Race and get yours!
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Post by TinyT » Sun Jul 03, 2011 10:04 am

PinkNinja wrote:^oh look. You're a dick on here just like HT.
oh you lock it up.

eazye- yes im a cheating whore and i spread my worthless asshole comments all around.

alonso- **** looks proper!

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Post by Jackasknissan » Sun Jul 03, 2011 9:23 pm

TinyT wrote:Lol @ welders pointing out the blatantly obvious to each other. Oh head flanges can warp when you weld them? get outta here! you crazy.
actually a machinist,, just do a fair bit of tiggin when it counts for buildup( cast, brass,stainless, impacto
and jigs/ fixtures. of course

alonso, get the manifold done yet ?
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Alonso
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Post by Alonso » Fri Jul 08, 2011 12:29 pm

I wished I was done lol. Getting closer little by little...

Here's where I'm at now...
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Billet PTE 6765 divided T4, Nismotronic, Speed density, Coil on plug conversion.

AWS D17.1 certified ;)
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Post by airman » Sat Jul 09, 2011 1:44 pm

My God. Gorgeous

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Post by 187MotorSports » Sat Jul 09, 2011 8:24 pm

Sick work, I feel dumb now questioning your welds on the Intake manifold i bought from ya. :shock:

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Post by O&Jperformance » Tue Jul 12, 2011 7:38 pm

Really good work and believe I being around fabricators a looooong time I like what you have done so far.
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Post by supakat » Tue Jul 12, 2011 7:44 pm

187MotorSports wrote:Sick work, I feel dumb now questioning your welds on the Intake manifold i bought from ya. :shock:
LOL. Yea this is sick and deep penetration. LOL
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Post by Bubba » Wed Jul 20, 2011 9:34 am

I'll be signing up for a welding class locally in hopes of one day building something half as nasty as this beast you've brought into this world. I'll never run a T4 on my engine and I'm still jealous of this manifold. One day...

Time to start hanging with all of the old skool fabricators and welders in my area. I'm bound to find someone willing to show me some tricks that will help me out.
My car is dead stock.... ish

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Post by Alonso » Tue Aug 23, 2011 4:34 pm

Teaser...
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Inconel 625 3" to 4" transition welded to Stainless V-band flange, Inconel 625 filler rod :wink:
Billet PTE 6765 divided T4, Nismotronic, Speed density, Coil on plug conversion.

AWS D17.1 certified ;)
Follow me on Instagram: @alonso240

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Post by sdaigle240 » Tue Aug 23, 2011 6:29 pm

Your a machine!
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Post by sicks13 » Wed Aug 24, 2011 9:21 am

You should take a welding class... :lol:
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Post by Alonso » Wed Aug 24, 2011 4:45 pm

sicks13 wrote:You should take a welding class... :lol:
I'd school everybody there including the instructor lol

Test fitted the 4" downpipe today, not fully welded yet-
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Hopefully I have a chance this weekend to upload more pics and get this thread caught up.
Billet PTE 6765 divided T4, Nismotronic, Speed density, Coil on plug conversion.

AWS D17.1 certified ;)
Follow me on Instagram: @alonso240

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Post by superDorifto » Wed Aug 24, 2011 8:25 pm

Alonso wrote:Teaser...
Image

Inconel 625 3" to 4" transition welded to Stainless V-band flange, Inconel 625 filler rod :wink:
We make a lot of our jet engine parts out Inco 625, not that common on cars, but if I had a "nickel"....haha

whatever lame joke,... I know.

You shoulda went baller and went Inco 718 or straight Waspalloy or MP159.

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Post by Alonso » Sat Aug 27, 2011 7:57 pm

Originally 718 was going to be used, but 625 is stronger and rated for higher temps.
Billet PTE 6765 divided T4, Nismotronic, Speed density, Coil on plug conversion.

AWS D17.1 certified ;)
Follow me on Instagram: @alonso240

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Post by Alonso » Sun Aug 28, 2011 12:14 am

Alright, picture time! I'll be picking up (kinda) where I left off

Holes for WG ready
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FFwd to now, manifold is fully welded
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FWD and AFT WG Dumptubes. They are 2.000dia x .035wall 321 Stainless.
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Downpipe, still work in progress... 4.000dia x .028wall Inconel 625.
Transition is spun Inconel 625, 3" to 4" dia, .035 wall nominal
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Weld on SS Vibrant Vband flange to transition, Inconel 625 filler rod
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Penetration
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As you can see by the following pics, even without AC and PS it get crowded fairly quick :shock:
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That's where the project currently stands. The downpipe will be made to follow the contour of the firewall, under the car it will get SS vbands throughout and after the flex bellows the material will switch to 321 stainless 4.000dia x .028wall tubing for the rest of the exhaust system.

FACK I still have a lot of work ahead of me lol :x
Billet PTE 6765 divided T4, Nismotronic, Speed density, Coil on plug conversion.

AWS D17.1 certified ;)
Follow me on Instagram: @alonso240

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Post by supakat » Sun Aug 28, 2011 5:53 am

Awesome job. That setup is gorgeous. Are you going to make an intake as well?
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Post by superDorifto » Sun Aug 28, 2011 1:40 pm

Alonso wrote:Originally 718 was going to be used, but 625 is stronger and rated for higher temps.
yes and no, 625 is a bit more ductile, but 718 has a higher ultimate strength, but 625 can handle thermal stresses much better. They are both rated for ~1200 deg F continuous operation, we use them pretty much interchangeably on our stuff...if the structural analysis shows the part failing to meet full life, a material swap to 718 usually fixes the issue - and adds a ton of weight.



- but either way the set up looks pretty impressive, when Im done with my SC build def want to go a similar route.

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Post by Alonso » Sun Aug 28, 2011 7:48 pm

I did some research on their properties, from what I gathered Inc625 seemed like the best choice for this application. I believe I saw somewhere that 625 would take 1600*F no problem compared to 718 only being good to 1300*F. Also 625 is easily welded to dissimilar metals, 718 I was unsure about and couldn't find anything to confirm that it could be.

I too think either would have been fine, its only gonna be a street/strip beast running on e85 not a JSF F-35 :lol:
supakat wrote:Awesome job. That setup is gorgeous. Are you going to make an intake as well?


That's the plan. I haven't sat down and designed anything yet although I do have some ideas floating in my mind. I was told if I designed parts using CATIA V5, like the intake mani head flange for example, we can get them machined in house 8)
Billet PTE 6765 divided T4, Nismotronic, Speed density, Coil on plug conversion.

AWS D17.1 certified ;)
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Post by supakat » Sun Aug 28, 2011 7:52 pm

Nice. Great to have technology readily available.
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Post by superDorifto » Wed Aug 31, 2011 7:33 am

Alonso wrote:I did some research on their properties, from what I gathered Inc625 seemed like the best choice for this application. I believe I saw somewhere that 625 would take 1600*F no problem compared to 718 only being good to 1300*F. Also 625 is easily welded to dissimilar metals, 718 I was unsure about and couldn't find anything to confirm that it could be.

I too think either would have been fine, its only gonna be a street/strip beast running on e85 not a JSF F-35 :lol:
supakat wrote:Awesome job. That setup is gorgeous. Are you going to make an intake as well?


That's the plan. I haven't sat down and designed anything yet although I do have some ideas floating in my mind. I was told if I designed parts using CATIA V5, like the intake mani head flange for example, we can get them machined in house 8)
agree'd, as soon as read that you were using inco for the DP, I was like, "oh a proper build."

I've been helping with some design work on the Lightning, and EVERYTHING is inco....the tubes, the brackets, the bolts...its actually pretty awesome.

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Post by blacks13coupe » Wed Aug 31, 2011 10:20 am

This setup looks awesome, very nice manifold. My only concern is the very tight tolerances between the piping and the strut tower / steering shaft, might cause issues when the motor torques. But it is hard to get a good idea from just the pictures.
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