:::RHMT::: Real Home Made Turbo

General Category => Fabrication => Topic started by: Stein on March 09, 2009, 08:47:01 AM

Title: My take on the Weld El Manifold
Post by: Stein on March 09, 2009, 08:47:01 AM: I thought that I would post up my version of the weld el mani.

This is for my 99 Miata DIY turbo project. Elbows are stainless from Ace Stainless and flanges from Weirtech.

I didn't want to do the usual "two 90's into two tees" as the flow from cylinder one just bashes into the flow from four at the outlet, so I used six 90* elbows.

I started with four elbows tacked into two pair. I cut an angle at the bottom (about 3/8" off of the inside edge) that would allow the two to come together enough that the exit matched up with the outlet flange.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture092.jpg&hash=f047bbbc813268d8196f74fd59aca60e2c68f73d)

Afte that, it was a matter of grafting the #2 and #3 elbows into the outer runners. This was all done by trial and error fit. After I got the tubes to fit, I marked out the placement of the runner onto the outer tubes and drilled two 3/4" holes and then opened the rest up with a die grinder and a carbide burr.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture115.jpg&hash=6a6b2e7245637be29cb98f66163e6b145734d294)

The head flange ends were ovaled to match the outlet ports in a vise.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture114.jpg&hash=30c16d4c7ae9abae3258bf64c791997e32f9288d)

After that, it was a matter of blending, deburring and prepping to weld on the flanges.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture116.jpg&hash=88bf09907821c86a796fe12c79531071367d2e74)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture117.jpg&hash=aeac6927d4f8cccb3161ddb38a26f70b6eb33829)

Head flange was then welded on. 309L filler rod was used to weld the stainless to the mild steel flanges.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture119.jpg&hash=d71302a91d8cae78b8bb74bc1c68fbf07b299b75)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture120.jpg&hash=ce513fb3f7f977da070b2cfe2916680a3001b6d3)

After the head flange was welded on, I was able to square up the outlet end and then weld on the outlet flange.

Here are a couple of shots after welding on the flange. I did not backpurge the mani when I welded on the flanges, so an occasional hickey on the inside. Here it is before any dressing of the inside welds.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture121.jpg&hash=1ebb24af8d783c531ab9813674add256508c9b80)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture122.jpg&hash=a304ac3608a9ae4b185f1984be924fe27b1229e8)

After it was finish welded, I polished it up with different wire wheels in my die grinder. It came out pretty good. I had about .040" out of flatness on the flange, so I took it to work and had a guy flycut the flanges so that they were flat and parallel.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture125-1.jpg&hash=2a02e3e30341b2f5cfbeced75cec52f3f0980418)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture126-1.jpg&hash=897a337027216c848819e83ce6feefb53b7a7c09)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture127-1.jpg&hash=0355f03f3cedd72de1f32ab356f39ca13f602b73)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture128-1.jpg&hash=557ea63de21be3748baef864a5fac1701d5fe84c)
(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture129-1.jpg&hash=73e9468c0bda98894d5248b126f3429cd81f0d36)

All in, I have $63 in the manifold. I have just finished the turbo install and have been working on tuning the car.

(https://realhomemadeturbo.com/forum/proxy.php?request=http%3A%2F%2Fi51.photobucket.com%2Falbums%2Ff357%2F68017%2FPicture214.jpg&hash=e882f30981561e43552158c13c658dcfe4719593)

The mani has held up fine so far. I am the first in the US using the Adaptronic ECU in an NB Miata, so it was a bit of a learning curve, plus there were no good maps out there other than a generic super conservative map.
Title: Re: My take on the Weld El Manifold
Post by: CSaddict on March 09, 2009, 09:05:31 AM: Great job on that manifold. I used to make those. Coping the center runners in nicely is kind of a pain. Nice work.
Title: Re: My take on the Weld El Manifold
Post by: weirtech on March 09, 2009, 10:38:21 AM: great writeup. manifold turned out well. i hate doing those #2 and #3 runners.
Title: Re: My take on the Weld El Manifold
Post by: doubleA on March 09, 2009, 10:41:08 AM: That turned out amazing. I love how short the runners are.
Title: Re: My take on the Weld El Manifold
Post by: snm95ls on March 09, 2009, 11:27:29 AM: That is tits!!

I love it man. I really wish I could see well enough to TIG.

:(
Title: Re: My take on the Weld El Manifold
Post by: turbob16hatch on March 09, 2009, 06:52:20 PM: looks very nice, you have some skill.

like everyone said, runners 2 and 3 are a bitch.
Title: Re: My take on the Weld El Manifold
Post by: glustic on March 09, 2009, 06:58:44 PM: Nice looking manifold! Hit me up if you wanna make me one for my civic. :D
Title: Re: My take on the Weld El Manifold
Post by: Blacksi on March 09, 2009, 09:56:10 PM: looks killer solid diy work
Title: Re: My take on the Weld El Manifold
Post by: Corey on March 10, 2009, 01:22:10 AM: mosty people use straight pipe for the middle 2 runners. the 1 and only manifold that style i made i did the same as you with the elbows and blended the holes so it was all smooth transitioning and fuck if i EVER build another one. it did work very well though.
Title: Re: My take on the Weld El Manifold
Post by: HiProfile on March 10, 2009, 01:57:42 AM: Wow, I was loving the post up til I saw the turbo. Fail. :-* Actually I'd bet it's the typical auto-x type miata, and feels more like a decent 2.4L NA motor.

Regarding the engine management, I'd have tried the Honda route (obviously!). Its starting to get more common to use an OBD1 Honda ecu with something like eCtune running the show, and typically involves the same wiring as the next standalone. Its just that pesky distributor placement on the Miata...
Title: Re: My take on the Weld El Manifold
Post by: cjernigan on March 11, 2009, 04:37:48 AM: Love that manifold, though I'm attracted to shiny things. How's it look after a few heat cycles Stein?
Title: Re: My take on the Weld El Manifold
Post by: onlyflash944 on March 11, 2009, 06:54:46 PM: nice manifold. what do you mean 'fly cut' the flanges?
Title: Re: My take on the Weld El Manifold
Post by: Stein on March 11, 2009, 07:07:19 PM: Quote from: cjernigan on March 11, 2009, 04:37:48 AM
Love that manifold, though I'm attracted to shiny things. How's it look after a few heat cycles Stein?

Actually it looks really good. Just a rainbow of blue, purple, gold when cold. Didn't get crusty looking at all. I'll try to get a shot.
Title: Re: My take on the Weld El Manifold
Post by: Stein on March 11, 2009, 07:09:35 PM: Quote from: onlyflash944 on March 11, 2009, 06:54:46 PM
nice manifold. what do you mean 'fly cut' the flanges?

I had a guy at work put it on a mill and machine the flanges flat and parallel. I'm the sales manager for a tool and die company and our work comp doesn't let me work in the shop any more. I used to be a tool and die maker. Kind of a bummer, but I still have friends at work that will hook me up.
Title: Re: My take on the Weld El Manifold
Post by: patsmx5 on March 12, 2009, 06:31:49 PM: Solid manifold Stein. 8)
Title: Re: My take on the Weld El Manifold
Post by: dive_miguel on March 12, 2009, 10:54:58 PM: Thats the shit i am talking about. :yes:

That looks like the magazine shit.
Title: Re: My take on the Weld El Manifold
Post by: caged on March 13, 2009, 03:54:51 AM: looks good, I tried doing it that way 1 time and as everyone else said never again :yes: