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Posted: Wed Jun 22, 2011 7:32 pm
by eazye2000
Alonso wrote:Sorry its a one-off, for my own personal abuse only :twisted:
....abuse, or personal satisfaction? lol

Posted: Wed Jun 22, 2011 8:29 pm
by Alonso
Well, both lol.

Posted: Wed Jun 29, 2011 5:22 pm
by Alonso
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

Posted: Thu Jun 30, 2011 12:47 am
by Jackasknissan

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

Posted: Fri Jul 01, 2011 8:38 pm
by Alonso
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...

Posted: Sat Jul 02, 2011 11:04 am
by PinkNinja
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.

Posted: Sat Jul 02, 2011 3:47 pm
by TinyT
Lol @ welders pointing out the blatantly obvious to each other. Oh head flanges can warp when you weld them? get outta here! you crazy.

Posted: Sat Jul 02, 2011 6:49 pm
by PinkNinja
^oh look. You're a dick on here just like HT.

Posted: Sat Jul 02, 2011 7:40 pm
by eazye2000
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!

Posted: Sun Jul 03, 2011 10:04 am
by TinyT
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!

Posted: Sun Jul 03, 2011 9:23 pm
by Jackasknissan
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 ?

Posted: Fri Jul 08, 2011 12:29 pm
by Alonso
I wished I was done lol. Getting closer little by little...

Here's where I'm at now...
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Posted: Sat Jul 09, 2011 1:44 pm
by airman
My God. Gorgeous

Posted: Sat Jul 09, 2011 8:24 pm
by 187MotorSports
Sick work, I feel dumb now questioning your welds on the Intake manifold i bought from ya. :shock:

Posted: Tue Jul 12, 2011 7:38 pm
by O&Jperformance
Really good work and believe I being around fabricators a looooong time I like what you have done so far.

Posted: Tue Jul 12, 2011 7:44 pm
by supakat
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

Posted: Wed Jul 20, 2011 9:34 am
by Bubba
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.

Posted: Tue Aug 23, 2011 4:34 pm
by Alonso
Teaser...
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Inconel 625 3" to 4" transition welded to Stainless V-band flange, Inconel 625 filler rod :wink:

Posted: Tue Aug 23, 2011 6:29 pm
by sdaigle240
Your a machine!

Posted: Wed Aug 24, 2011 9:21 am
by sicks13
You should take a welding class... :lol:

Posted: Wed Aug 24, 2011 4:45 pm
by Alonso
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.

Posted: Wed Aug 24, 2011 8:25 pm
by superDorifto
Alonso wrote:Teaser...
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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.

Posted: Sat Aug 27, 2011 7:57 pm
by Alonso
Originally 718 was going to be used, but 625 is stronger and rated for higher temps.

Posted: Sun Aug 28, 2011 12:14 am
by Alonso
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

Posted: Sun Aug 28, 2011 5:53 am
by supakat
Awesome job. That setup is gorgeous. Are you going to make an intake as well?

Posted: Sun Aug 28, 2011 1:40 pm
by superDorifto
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.

Posted: Sun Aug 28, 2011 7:48 pm
by Alonso
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)

Posted: Sun Aug 28, 2011 7:52 pm
by supakat
Nice. Great to have technology readily available.

Posted: Wed Aug 31, 2011 7:33 am
by superDorifto
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.

Posted: Wed Aug 31, 2011 10:20 am
by blacks13coupe
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.