My exhaust manifold (WIP)

My exhaust manifold (WIP)

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Discussion

Dr.Hess

Original Poster:

837 posts

255 months

Sunday 22nd May 2005
quotequote all
If any of you'se guys not on the Yahoo list are interested, here are some pics of my exhaust manifold (work in progress). It is ready for TIG, which I sub out.

[pic]http://home.flash.net/~hess/images/Manifold_Tacked_001.jpg[/pic]
[pic]http://home.flash.net/~hess/images/Manifold_Tacked_002.jpg[/pic]
[pic]http://home.flash.net/~hess/images/Manifold_Tacked_003.jpg[/pic]
[pic]http://home.flash.net/~hess/images/Manifold_Tacked_004.jpg[/pic]

Umm, the shiney one is the one I made.

Dr.Hess

techspy

321 posts

257 months

Sunday 22nd May 2005
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Very nice! Keep us informed. I for one will place an order!

John
94 S4
www.skynetworks.gotdns.com

Dr.Hess

Original Poster:

837 posts

255 months

Monday 23rd May 2005
quotequote all
OK, I've done some checking around. Here's the deal:

My manifold is getting TIGed now, and is ready for early Alpha testing. Lets call it Alpha-1 stage. I can get it duplicated with a shop doing most of the real time consuming (to me) fitting and me doing some of the fabing, like the figure 8 port tubes. At this stage, it is still untested on the car, except for fitting. In order to duplicate it, I need to have it off the car so they can look at it and copy it. This means I can't put it on my car and use it. There may be issues with the design, construction techniques, materials, whatever. Remember, it is in Alpha at this point.

These things ain't cheap. The materials and labor adds up, and adds up fast. I can't afford to just have them knock out another one to play with. However, if anyone wants to be in the initial Alpha-1 test stage, here is what I can do: For $1000, I can get it duplicated. If someone wants to be a lab rat with me, contact me offline. Of course, no warranties implied or expressed including suitability of use, blah blah blah. I would like to see an alpha tester that uses it hard and does their own wrenching and can afford to take a one large gamble and not be pissed (at least at me) if it doesn't work out. Also should be CONUS (Continental US) for shipping purposes. I would estimate a delivery time of 2-3 weeks, could be quicker (doubful) or longer. Took me a little over a week just to get a flange set cut. I would have to get the flanges cut, do the holes on the turbo flange, put studs in, mount in the jig, fab the port tubes, order the 90's, bring it all to the shop and have them put it together.

Sorry to rush it, but I need to know in the next few days, because as soon as my exhaust gaskets and studs get in, I want to put the car back together. I have had enough down time as it is. So, any takers? I'm going to cross post this to Yahoo te too.

Dr.Hess

Dr.Hess

Original Poster:

837 posts

255 months

Thursday 26th May 2005
quotequote all
Here it is finished. Now I just need to get my gaskets in and put it back together.





Dr.Hess

arium

101 posts

248 months

Thursday 26th May 2005
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Looks like a fine bit of kit Dr. Hess!

I like the idea of extending the exhaust flange to make a bit of a crane for the turbo. Should help it from sagging.

Only q is.... how on earth will you get to all of the nuts on the exhaust studs? Or is the camera being deceptive to me?

Steve

Dr.Hess

Original Poster:

837 posts

255 months

Thursday 26th May 2005
quotequote all
I can get a socket on the top nuts. It is tight, and I did a little modding to a socket, but it should fit. The bottom ones on #1 can be done with a socket and the rest can all be gotten to with a box end wrench.

Dr.Hess

GKP

15,099 posts

246 months

Friday 27th May 2005
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Wow! Looks good. Keep the up the good work