johnny23toronto

I've finally set aside time and some materials to start my B18B turbo header... but its not looking good:

Here are my costs I have sourced out so far:
Prices in CANADIAN $.

(etd racing, markham)
B series Engine Flange: $80 (Mild Steel)
T3 Flange: $40 (Mild Steel)
T3 5 Bolt Typical Flange: $45 (Mild Steel)
A box of Schedule 40, 1.25 inch I.D. Weld-els, Mig wire, etc: $80

Sums up to $245.

Then, I'll piece and tack it together with my MIG.

Then, sending it out for TIG welds inside and out: $150 (I've recieved this quote from one company)

That totals, with taxes added on top, $454.00

Now I am thinking about simply buying one already built!

Any advice on how I can make this project less costly? I have a brother in the USA but if he gets caught with duty/taxes its not worth the risk...
I am HORNY to use my mig again!
I mean, I haven't even included a pre-fabricated 4 into 1 merge collector so that itself is going to be a fabrication nightmare. Can I skip out on the tig welding and stick with my 100 amp Mig and thick wire, both inside and outside where possible using 0.035 wire?

Oh, and I don't want my manifold to look like this (below):


Instead, I want it to look like this (Below):


Or at worse case, like this:



Frustrated,
-Johnny

P.s. Here are some of my fav links on "How-to" do this:
http://www.sdsefi.com/techheader.htm
http://www.bpestilence.com/turbo.htm
http://www.4agte.com/old_turbo_manifold_page.htm
http://www.80tq.com/other_conversions.html
http://92civic.tripod.com/
http://www.80tq.com/tube_header.html

punkindrublic

how thick is the tubing your planning on using?

johnny23toronto

Schedule 40 fittings are very thick, as is the Straight Schedule (SS) (not stainless steel) pipe. I would guesstimate it is over an 1/8th of an inch thick. Wayyy thicker than any exhaust pipe ghetto setup.

According to http://www.2quicknovas.com/turbos.html
weld-els have a thickness of about (29/2) = 0.14 inches. (in the 1 1/2 diameter).


That is equal to over 3.5 mm.

punkindrublic

you might be ok then, you only really need to tig stuff if its an exotic metal really or you want it to look perty... if its all mild steel though you should be ok... just practice on some spare tubing and make sure you are penetrating most of the way through

what kind of wire are you using for this?

johnny23toronto

Please, tell me if you know!

I used .023" on my car body work, but I still got a whole roll of 0.035 for free with the welder when I bought it. Of course I'm using only unshielded wire, with the proper gas. None of that flux coated crap!

punkindrublic

flux is good at times, at work i use a 2mm wire that is flux cored with 100% co2, usually around 32V and 380 amps... sure you have to chip the weld, but your weld itself is super super pure... the flux removes all the contaminents from the weld pool

so for outright weld strength a flux wire is usually better. in your case you would want those welds to be as strong as possible due to the exsessive heat they will take right? also make sure you dont hang the turbo off the manifold, make sure it braced to the engine by some means

the size of the wire isn't the biggest concern though, its more what its compossed of you know? i'm not sure if any companies make a wire that is designed specifically for exhaust applications though, or hot - cold things... what companies made the wire you have there now? and whats the code? it'll be something like E80T1

scarlemthug

$454CDN is not bad at all considering an equal length manifold will run u well over $600 US + shipping.

imported_zc_hatch

but you know the quality will be high and it will work.

that and you wont spend 10 hours making something that wont work as well as something that was another 100$

scarlemthug

Well your looking at about $800CDN to get the least expensive tubular manifold that i could find on H-t so your still saving $350 in the end. As long as you make your welds strong and everything i think it would be a fun project to do and would save you alot of money.

imported_kIeRaN

U'd also get the satisfaction of knowing u made your exhaust manifold. Which i think would be pretty cool

WayFastWhitie

The flanges can be sourced cheaper.

Its christmas time, put it as a 'gift' on the package you will be fine, they cant proove otherwise since its from your brother and he will say its a gift and the cash you sent him was for something else..

Anyways. 0.035" should be sufficent, id like to see how they person you send it to welds it inside and out. Outside is all thats required unless its 1" plate or thicker, then just V groove it.. Anyways.

Its mild steel, weld it with the mig! If your going to send it out atleast built it from stainless. Ceramic coat it afterwards. And rig up someway of bracing the turbo off the rad support or something.

Goodluck, i parted out making a log style manifold from stainless, using mandrel 1.75" bends. T3 flange, B series flange, Wastegate flange wasnt added, wasnt sure what i was going to use.

Mine came out to under 200 USD for supplies. Keep in mind i have a Tig machine and would weld it up myself.

Goodluck.

bbarbulo

iTrader: (2)

I did mine in SS304, so it basically looks like the last pic you posted. It was TIG welded professionally. It was a pain in the ***, and honestly, if I was to do it again, I'd just buy the damn thing from South Florida Pefrornance or something... but... at least it's stainless even if it is a log

later, I'll do a more elaborate one, but not in stainless.

scarlemthug

Bruno how much did it cost you in parts to do it yourself? Atleast its a tubular log and not a cast one :P.

bbarbulo

iTrader: (2)

close to 4 bills :-\ cuz don't forget you gotta have all the flanges and stuff CNC machined and stainless is not cheap to buy or to machine, or to weld.

scarlemthug

thats still not bad considering tubular logs like the BMCrace one go for $350US i believe.

bbarbulo

iTrader: (2)

plus many many hours of fabrication, and it still looks amateurish. plus calling in many many favours from friends. it's not worth the hassle. buy one, and it's bolt on and go. I've been working on the manifold for 2 years now. haha that's been the one peice that's held me up.

scarlemthug

the satisfaction of doing stuff yourself far outweighs spending a bit of time on building something IMO. Now get that **** put on the car and boost all the way to a KC meet:P.

Right now im stuck in the middle between saving up for an EL mani and 3" DP or getting a tubular log style and 2.5" DP. The log setup is about half the price of the EL but then the EL will be that much better i think.

imported_f4guy905

My buddy is making the last manifold that you showed. I picked up the metal for it and it only came too about $65. That was for 2- 90's and 2-T's, all schedule 40. I can't remember what the total cost of the manifold is going to be, but it will for sure be less then $300. Let me know if you have any questions about it, I am get you in contact with my friend.

Matt

b00st3d zc

I haven't read most of these, i basically skimmed to the bottom,
from what i have read you are Fuc|<ed...let me help you out alittle. This is a great forum but this will help you more then 100%

www.homemadeturbo.com/forum/index.php

I don't know if you have msn but add me
( chris_c241@hotmail.com ) and i will get you some MUCH better prices. let me know dude. I'm making a log mani right now and only have $100 into the WHOLE thing, header and turbo flange and schedule 10 piping, 40 is OVERKILL.
look forwrd to hearing from you
<chris>

EDIT>>>woops i didn't even read matt's post above me. he was only wrong about what schedule i used

imported_f4guy905

I just saw this manifold and figured if your going to make one, why not take it to the limits........



One bad-*** manifold!

MAtt