was gonna throw this in the fab thread but figured it would end up getting lost. bunch of shitty pics of a manifold i made yesterday, took about 17 hours not including the collector which i made a few days ago. the purpose of this is just to show the people who dont know and to kind of document it a little because i want to try to write an article for a mag. also will help people learning to fab/weld because when i was learning there really wasnt much help out there so the initial curve was very steep.
first few steps i didnt take pics of but kind of goes like this:
* weld up a collector
* fit it to whatever turbo flange you are using
* weld the flange while its bolted down (i usually just bolt it to a spare exhaust housing)
* brace the collector to the head flange in the location you want the turbo (i have just made an L - bracket that bolts to the t3 flange that is reusable then just bolt a piece to that and weld a rod to the flange. very easy to do and easy to clean up when done
* start on the first runner. doesnt really matter which one just make sure you have an idea of how everythings going to look in your head before you start
heres my first runner ready to weld. it is very important to bevel all the pieces at least 3/4 of the way down to make sure you have good penetration. it is also important to have all of your bevels consistant in width and depth as this will make the welding look much more consistant when finished.
also a few pics of my purge T and kind of how i purge when im welding the runners. also a pic of the champagne nozzel i use on the torch. the wide nozzel really helps on pipe to get more gas coverage during each pass. each pass i make in pipe is sually about an inch as a time.
oh, also a pics of the pipe before and after wire wheeling. i do this after mockup of the runner right before its welded.
then on to the next runner until all 4 are done and tacked to the collector and head flange.
on longer runners where i know there will be a tendency to warp i will actually weld half od the runner before completing the other half. this help to reduce making changes after welding.