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Author Topic: How to: cut a collector  (Read 8332 times)

weirtech

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How to: cut a collector
« on: March 11, 2009, 09:29:34 PM »

How to make a collector using 304ss 1.5” schedule 10 pipe for a T3 flange.

This is meant as a guideline for building a collector.  Always put safety first and wear proper PPE while working with tools and equipment.  This is only one way to make a collector.  Everyone has their own method, but I have found this way works for me and perhaps it can help you too.  I use a vertical band saw, but the same theory can apply to a vertical band saw or a chop saw.

1.Decide on the length and angle of your collector.  In most cases, a longer collector with a more gradual merge angle is ideal, but sometimes space does not allow for it.
2.Cut all your pipes for your collector.  I set a stop at one side of the table to ensure all the pipes are the same length.
3.Face the end of the pipes and chamfer.  I use a lathe, but a belt sander can work too.



Be sure to deburr the inside of the pipe after this step.

4.Measure the distance across the short side of your turbo flange inlet, divide that # by 2 and this will be the distance from one side of the pipe that you will cut your angle to.
5.Set up your saw to cut the first angle.  I like to put a stop on one side of the pipe to butt it against so they are all consistent.  I use some vise grips to hold the pipe while cutting so to avoid losing any fingers.



6.After the first angle is cut on all 4 pipes you may be left with a small step at the end of the cut.



To flatten it out I just put it on the belt sander to smooth the last bit out.



Here is a comparison of before and after.



Be sure to deburr the inside of the cut as well.

7.Wire brush your pipes at this point.  I use a brass wire wheel on a bench grinder that I only use for stainless pipe.  Using it for other materials can contaminate your stainless when you weld it.
8.Tack weld two of each of the pipes together in 4 places.  I use a couple blocks on the welding table to keep them from rolling away from each other.



9.After your two pairs of pipes are tacked together the next angle will be cut for the bottom of the merge that meets the flange.  I typically eyeball the distance from the midpoint of the inlet in the flange to the top of the lip of the pipe so it will lean far enough away from the center of the flange inlet so it doesn’t interfere with the other pipes.  This pipe is cut, but it gives you an idea of what is needed.



For the setup on the saw I use two stops clamped to the table.  The first stop is used to lift the pipe merge to the desired angle.  The second stop is used to keep the cut length consistent between all cuts.  Here are some different angles during the cut.





10.The third and last angle only requires one stop on the saw, since the bottom of the merge is flat to match your flange inlet.  I choose to do it standing up just because I find it easier, but it could also be done lying the merge on its side with a spacer under the narrow end.  Here are some different angles of the cut being made.





11.The end result should look something like this, but you aren’t finished yet.



When you lay the flange over top of the collector pipes it should sit flat and if your measuring was on, it should poke inside the inlet slightly on the sides.



There are a couple different ways to flatten these out.  One way is to just squeeze the sharp points flat in a vise.



Another way is to partially weld the pipes to the flange and use the round end of a ball peen hammer and hammer them out to match the port in the flange.  I usually do this to push the pipe out of the port in the corners.  The end result should look similar to this.





12.The finished collector should look something like this.




Usually, I leave the collector unwelded until I know I don’t need to break it apart to build a particular manifold it is being used for.  Some people prefer to weld them up right away, but sometimes haste makes waste.

I hope this helps, good luck!
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jdmhatchracer94

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Re: How to: cut a collector
« Reply #1 on: March 11, 2009, 09:38:31 PM »

yeah it does now sell me one
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Corey

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Re: How to: cut a collector
« Reply #2 on: March 11, 2009, 10:34:46 PM »

wow aaron you make collectors the hard way. maybe ill do a write up on how i do mine.
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1Fast68

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Re: How to: cut a collector
« Reply #3 on: March 12, 2009, 12:37:21 AM »

Man i wish i had a shop with some decent tools.
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Blacksi

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Re: How to: cut a collector
« Reply #4 on: March 12, 2009, 08:31:48 AM »

your bandsaw = sex
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Loki

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Re: How to: cut a collector
« Reply #5 on: March 12, 2009, 01:20:49 PM »

Man i wish i had a shop with some decent tools.


Me too.
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dvst8r

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Re: How to: cut a collector
« Reply #6 on: March 12, 2009, 01:27:15 PM »

I wish I had some time to use the tools I have.
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CSaddict

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Re: How to: cut a collector
« Reply #7 on: March 12, 2009, 04:43:24 PM »

wow aaron you make collectors the hard way. maybe ill do a write up on how i do mine.

I actually just welded together a collector CoreyR gave me. (We borrow mani parts back and forth). It fits minty.
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caged

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Re: How to: cut a collector
« Reply #8 on: March 13, 2009, 03:42:32 AM »

Great write up :). I have the same belt sander, one of my most used tools. :noel:
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dvst8r

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Re: How to: cut a collector
« Reply #9 on: March 13, 2009, 10:30:38 AM »

wow aaron you make collectors the hard way. maybe ill do a write up on how i do mine.

Please do. The more ideas the better.
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jarban

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Re: How to: cut a collector
« Reply #10 on: July 28, 2009, 08:23:53 AM »

CoreyR, You going to make the guide ? I am about to make a collector now and was wondering how you did it. Even a small write-up without pics would do.
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turbob16hatch

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Re: How to: cut a collector
« Reply #11 on: July 28, 2009, 08:45:56 AM »

i can take some pictures of my jigs, there super simple and require 2 steps to complete.

i will get them this morning.
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bigwig

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Re: How to: cut a collector
« Reply #12 on: July 28, 2009, 07:48:42 PM »

Simple jigs = square collectors.  T3 flange is rectangular.  This shouldn't matter for most, but some get sensitive about such things.
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turbob16hatch

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Re: How to: cut a collector
« Reply #13 on: July 29, 2009, 02:00:59 AM »

ok here is one of my jigs, there not perfect but they work fine.

ok here is the jig, i used washers to locate the jig onto my band saw.


here you can see how you mount the pipe onto the jig, the tab on the right acts as a stop and holds the front of the pipe. make sure you can clamp so the pipe stays flat. i have made this mistake before and it ruins your repetability.


After your first cut rotate the pipe 90*. now i don't get to high tech here, just turn the pipe untill it is level on top.


you can use a protractor to get close on the angle of the cut needed.



eh hope this helps
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danz

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Re: How to: cut a collector
« Reply #14 on: August 10, 2009, 07:34:49 PM »

it does help.  nice jig.
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t_cel_t

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Re: How to: cut a collector
« Reply #15 on: August 10, 2009, 08:56:37 PM »

yeah that is an awesome jig, i need to make one
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ADSR

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Re: How to: cut a collector
« Reply #16 on: September 14, 2009, 10:35:54 PM »

Damn good info!

I'll be making a jig this weekend.
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ADSR

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Re: How to: cut a collector
« Reply #17 on: September 14, 2009, 10:44:56 PM »

Hmm.. one question about this jig.  Is it flat all the way accross, or is it up at the back of where the pipe sits? Is this just a miter cut? Or a miter and bevel?

Thanks guys
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Corey

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Re: How to: cut a collector
« Reply #18 on: October 14, 2009, 12:28:01 AM »

i took some pics of my jig and the end product tonight because i was in a picture taking mood.

jig is just a piece of angle iron with a piece welded at the end for a stop and a nub of 3/8 round stock to hold the pipe in place, and a pair of needle nose vise grips on the other end to keep it clamped. all the holes on it are for different angles for collectors which i do by eye.




this is the second cut on the collector which is supposed to be 90* fromt he first. i dont have any marks or stops for this cut so i line it up by eye cause im good like that. i highly doubt anyone could use my jigs but me because of this.




finish cut and just tacked together before and after being deburred.





all this is done a $200 harbor frieght band saw that ive had for a few years now. still cuts great.


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ryan89crx

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Re: How to: cut a collector
« Reply #19 on: October 14, 2009, 12:33:02 AM »

damn, looks nice Corey
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danz

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Re: How to: cut a collector
« Reply #20 on: November 20, 2009, 01:06:31 PM »

thanks for the pics of the O0 jigs.  these are so easy and sweet.

what types of chop saw blades are best for this?  i could taste iron the next day.. lol


jig



4.5 collector cut at 11deg.  too tight up top.  changed angle to 14deg, will make new collector tonight most likely.

« Last Edit: April 29, 2010, 03:52:59 AM by danz »
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patsmx5

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Re: How to: cut a collector
« Reply #21 on: November 21, 2009, 09:30:18 PM »

thanks for the pics of the nig jigs.  these are so easy and sweet.

what types of chop saw blades are best for this?  i could taste iron the next day.. lol


jig


Got any more pics of your jig? I basically want to copy it and put it on my abrasive cutoff saw. :)
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turbob16hatch

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Re: How to: cut a collector
« Reply #22 on: November 21, 2009, 10:23:07 PM »

Just look up the thread where i posted my jig, pretty sure there the same more or less. It's works haha
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danz

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Re: How to: cut a collector
« Reply #23 on: November 21, 2009, 10:34:25 PM »

pic of jig



new collector... perhaps a bit too spread out.  we went with 4inch this time.  might have been better off with 3.5



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patsmx5

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Re: How to: cut a collector
« Reply #24 on: November 21, 2009, 11:06:19 PM »

Looks good. I see it's simple. For some reason I didn't see it right when I looked earlier. Guess I should sleep more often.  :P
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Quote: Originally Posted by Adam Hopkins
There is no such thing as too much boost. You could have too little rod, piston, or sleeve. But never too much boost.

speedfoos

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Re: How to: cut a collector
« Reply #25 on: November 24, 2009, 09:41:43 AM »

Good DIY. I'm posting so I can use this thread as a reference when make a set of 4-2-1 collectors for a build I'm doing right now.
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danz

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Re: How to: cut a collector
« Reply #26 on: November 24, 2009, 04:39:25 PM »

Good DIY. I'm posting so I can use this thread as a reference when make a set of 4-2-1 collectors for a build I'm doing right now.

better make a new thread and post porn and boosted crx's quick before someone notices.   :?:
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speedfoos

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Re: How to: cut a collector
« Reply #27 on: November 25, 2009, 10:00:10 AM »

Naw. While I am DIYing everything, my build has no place on this forum.
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PhilStubbs

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Re: How to: cut a collector
« Reply #28 on: November 25, 2009, 06:02:22 PM »

you either have a show car or no boost. everything else fits on this forum
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CSaddict

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Re: How to: cut a collector
« Reply #29 on: November 25, 2009, 06:37:39 PM »

Naw. While I am DIYing everything, my build has no place on this forum.

Good, you get my nomination for the next Banhammer Wednesday vote.  :P

P.S. you are right, no one cares to see you hop up your Power Wheels Barbie Jeep.
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