My 16v build, continued

[PapaJo]

thank you, think it came out ok regarding it's my first manifold ever, still lots of work
to make it look the part though

Well done!! For a first try it looks very good and will do the job just fine.

I´m sure you have a plan to cover the fuel lines with some heat resistant protection as the exhaust will be passing down on that side.

May I also suggest that you put a support bracket, flat bar on either side of the turbo flange to the head flange side where possible to assist in preventing welds to crack with flex that will occur between motor and exhaust downpipe.

[ob wan]

thanks, plan is to move the fuel lines and brakeline that passes below the brake bar. oh and the steering knuckle will definitely need some sort of heat shield...

yep I forgot about supports, will put some in on Friday, then it's time for the wastegate and downpipe...

was thinking of machining the hole where the internal wastegate would have been, bigger to about 32 to 38mm if possible, then fitting the external wastegate directly to the flange so that it uses the passage right before the exhaust wheel as a "collector"... need some input on that and on having a "screamer pipe" or not

the exhaust will be 63mm as that is the size of the outlet

but overall I'm pretty happy thus far

[ob wan]

so basically fitting the EW to the spot where the X is on the outer flange and the port matched to the ID of the EW, obviously not welded shut like in the pic...

[ob wan]

[PapaJo]

That will work, all you need to do when doing this is make an insert or longer piece through the flange that is press fit into this hole to ensure you don´t get blow by gasses leaking to prevent boost drop off when turbo spools higher. Plumb the pipe back into exhaust with a narrow angle in same direction as exit flow to get the least back pressure when blow off opens. It will be advisable to put a flex joint on the exhaust line and also on the BOV piping before BOV joins back into the exhaust piping. This help to prevent cracks and allow expansion on flex with heat.

[panic-mechanic]

The only issue with doing this as per picture is the amount of heat generated that is sitting right under the wastegate diapraghm.
i have seen a few fail in that kind of setup. So try to at least move the wategate away from sitting directly next to the main exhaust pipe.

[PapaJo]

The only issue with doing this as per picture is the amount of heat generated that is sitting right under the wastegate diapraghm.
i have seen a few fail in that kind of setup. So try to at least move the wategate away from sitting directly next to the main exhaust pipe.

Most BOV manufacturers suggest minimum of 100mm space.

[ob wan]

atleast now there is space to move it away, will tack it in place, away from the turbo and exh, take a pic and post it...

[PapaJo]

atleast now there is space to move it away, will tack it in place, away from the turbo and exh, take a pic and post it...

[ob wan]

Is a BOV not a dump valve?

[PapaJo]

Is a BOV not a dump valve?

Correct,

Meant waste gate.

[ob wan]

[ob wan]

[PapaJo]

Is the waste gate done?

[ob wan]

Not yet, busy with internals, took the week off so should be starting by friday

[Donavan]

Some advice,

Don't use allan caps on your exhaust to turbo flange.

Those bolts tend to seize due to heat and they will strip very easily.

Rather use a stud with a copper nut as it is easier to remove.

[ob wan]

Some advice,

Don't use allan caps on your exhaust to turbo flange.

Those bolts tend to seize due to heat and they will strip very easily.

Rather use a stud with a copper nut as it is easier to remove.

Thanks, will do

[Cornel]

SUB

nicely done so far!

[ob wan]

Pistons hit the cooling nozzles so had to fix that, head is back on, busy fitting the wastegate, need to go get some heat wrap

[ob wan]

SUB

nicely done so far!

Thank you

[ob wan]

Is it worth heat wrapping the exh manifold and down pipe?

[PapaJo]

Is it worth heat wrapping the exh manifold and down pipe?

I´m not in favour of heat wrapping as it tend to keep the heat inside and then lead to cracks on the welds.
More heat inside the manifold seems to be better performance wise for turbine spool up as exhaust gasses are at higher temperature and expanded more.
It does help to keep the heat away from other components though.
Some you win, some you loose.
You will get mixed comments from this discussion. Decide what is best for you and go with that.

[ob wan]

went with the traditional way of fitting the wastegate... less hassles around the fuel lines...
finishing up the exhaust and boost pipes tomorrow, need to find heatwrap-type sleeving for the hoses and tubes, still planning
the heat shield for the steering knuckle

[ob wan]

oh and I fired her up this afternoon, just to check for leaks and noises....


pic of the internals, arp rod bolts and new big ends also in.

btw please excuse the filthy engine bay and motor, normally gets a proper cleaning every weekend

[PapaJo]

Word of caution here.

Don´t forget the heat shield or cover for the clutch cable end plastic. That may get melted after a few spirited drives.

Quote from a turbo site:

"In general, the larger the oil drain, the better. However, a -10AN is typically sufficient for proper oil drainage, but try not to have an inner diameter smaller than the drain hole in the housing as this will likely cause the oil to back up in the center housing. Speaking of oil backing up in the center housing, a gravity feed needs to be just that! The oil outlet should follow the direction of gravity +/-35° when installed in the vehicle on level ground. If a gravity feed is not possible, a scavenge pump should be used to insure that oil flows freely away from the center housing."

Difficult to see from your picture and it appears to be less than +/- 35degrees as recommended.