Shop Life 2.0

[HipMF]

m42b32 said:

I think jakeb/classic daily makes an m42 e21 turbo manifold with his turbo kits, not sure if he still sells them (or sells them separately) https://www.r3vlimited.com/board/showthread.php?t=259174

This could be an option, but I like to fab stuff, so I'll probably make my own.  Also gives me the flexibility to mount the turbo where I want it (currently undecided).

[HipMF]

Craptastic header mock-up v0.2 complete

The PVC didn't work out as well as I thought it would. I couldn't get it to bend tight enough without kinking, or get a consistent radius bends. Regardless, I was able to figure out how to route things. There's not a lot of room on that side of the engine, but I was at least able to verify that I will be able to build something that will fit in the chassis.

Still need to get flanges made, but I'm hoping to be able to start round 1 of header fab next weekend.

[Bassboy3313]

filling the PVC with sand, capping the ends and using a little heat while bending helps keep the PVC from kinking. But either way, looking good!

[Jdesign]

That's how they make jacked race headers for boats. They have two tubes, one inside the other, and fill the void with sand before bending. The only difference here is that its PVC and not stainless.

[HipMF]

Started out the weekend by trying to impulse-buy a band saw, but couldn't find anything locally that didn't look like more trouble than it would be worth. So, we're back to doing things the Mike way (aka the hardest way possible).

I picked up a bunch of 2.5" radius U-bends, so first order of business was to come up with a way to cut them straight and square so that they mate together nicely. Not having gaps where the tubes butt together should make it a lot easier to weld. I decided a jig that the tube could sit in with a slot to hold the sawsall blade straight would probably work.

I've only tried it once so far, but it seems to work really well. Better than expected actually.

The next hurdle was to figure out how to oval the end of the tubes so that they can mate up nicely to the exhaust ports on the head. I had researched this one a while back, and the best solution I found was to create a die that's the same shape as the port, and then hammer the tube down onto the die.

Decent!

The last area that I'm concerned about is the collector. The tubes need two long tapered cuts at 90 degrees to each other. I had basically given up on figuring out how to do it with the tools I have and was going buy a stationary belt/disc sander to mount a jig to, but at the last minute I came up with a different plan.

Ben is very concerned for my safety, and I'm willing to admit that this probably isn't one of my best ideas. I gave it a go with some PVC, and it seems to work well enough. The cuts aren't super straight, and will need some hand-finishing. I was also eye-balling the 90 degree turn for the second cut, so it didn't turn out perfect, but if I can figure out a better way to do that it should be good enough to get by.

I still haven't gotten flanges made, so I couldn't really start building anything yet, but I'd say it's going pretty well so far.

[YoungCR]

I envy your craftsmanship but you're also crazy!

[B C]

Very impressive ingenuity as usual!

Perhaps these may be helpful?

its not the way its usually merged for a turbine flange but it may prevent a headache or two

https://caautoparts.com/products/2-25-4-4-1-exhaust-merge-collector-excol-225-4-ss?variant=40443660105&gclid=EAIaIQobChMI8bGJ4IPg3gIVhbjACh1EFQBcEAQYCSABEgJpxPD_BwE

[Jdesign]

Might I suggest a band-saw? No really, You work a few blocks from me and I should have everything you need here besides your car. Mark what you need cut and shoot me a text and come cut it. ;D

[suspenceful]

I enjoy the DIY-style of your builds.

I also think you would benefit from a band saw.

[Bassboy3313]

band saw for sure. I ended up getting the portaband from Harbor freight. Slapped a Milwaukee blade on it and welded up a stand for it as well. Works wonders for these kinds of things.

[HipMF]

snap said:

Very impressive ingenuity as usual!

Perhaps these may be helpful?

its not the way its usually merged for a turbine flange but it may prevent a headache or two

https://caautoparts.com/products/2-25-4-4-1-exhaust-merge-collector-excol-225-4-ss?variant=40443660105&gclid=EAIaIQobChMI8bGJ4IPg3gIVhbjACh1EFQBcEAQYCSABEgJpxPD_BwE

If I fail at DIYing one, I could do something like that, but I don't accept defeat easily...

There isn't really a need to transition to a round tube, because the turbo inlet is kind of square-ish anyway. I planned on cutting the turbo flange to the shape of the pipes to make life easier.

[HipMF]

Jdesign said:

Might I suggest a band-saw? No really, You work a few blocks from me and I should have everything you need here besides your car. Mark what you need cut and shoot me a text and come cut it. ;D

This could be an option.

The problem isn't as much the tool that's being used to do the cutting as it is holding the tube in the proper position while it's being cut. Even if I had a nice bandsaw, I would still need a "sled" to hold the tube at the correct angle, and a way to rotate it exactly 90 degrees before making the 2nd cut.

[Jdesign]

HipMF said:

This could be an option.

The problem isn't as much the tool that's being used to do the cutting as it is holding the tube in the proper position while it's being cut. Even if I had a nice bandsaw, I would still need a "sled" to hold the tube at the correct angle, and a way to rotate it exactly 90 degrees before making the 2nd cut.

That's very true, but I find it hard to imaging that Frankenstein clever set up you have not shaking you into a seizure while trying to make a precise cut. 

[HipMF]

Bassboy3313 said:

band saw for sure. I ended up getting the portaband from Harbor freight. Slapped a Milwaukee blade on it and welded up a stand for it as well. Works wonders for these kinds of things. 

Was checking these out and they look pretty decent actually. The porta-bands I've used have been way better saws than any of the cheap band saws I've ever used.

[GunMetalGrey]

That watermark is way too coincidental, also looks way to legit to have your name on it
That being said, seems like you could have better results with a setup like that.

[HipMF]

Merge collector saga continues...

I came up with a jig to use the sawzall contraction to cut the tubes (piece of angle iron, some door shims, and electrical tape). Tried it out and was not satisfied with the results. After that, I came up with a different plan to make a jig with the CNC router and the mill at work. However, in the interest of actually getting something done, I changed my mind and just did it the way I usually do things. The hard way.

Everything needed to build a merge collector:

Many hours spent on this. Will just buy a collector next time.

I forgot the camera at home, and didn't take any in-process pictures. The results turned out okay though. Some small gaps, but shouldn't cause a problem.

Next step is to make a turbo flange. After that I'll finally be able to do the fun part.

[HipMF]

Mill-drill sending a 1.5" holesaw cup through 3/8" steel like it was butter.

The trick with hole saws is to set the RPM as low as it will go and leave the belts loose to act as a clutch in case things go south. Very little heat generated, and the cup is still sharp. Could probably do this all day without wrecking it, compared to using a drill press which will burn it up trying to up drill through sheet metal...

[HipMF]

Did some precision sawzalling

Finished up with the grinder.

Flattened out the top of the collector and tacked that on.

And started running some tubes.

Looking good so far. Unfortunately it will have to come back apart to get welded. I'll have to pull the collector apart to weld 360 degrees around the tubes that connect to it. It'll be a challenge to get at everything that needs to be welded. Will definitely have to sit down and practice on some scrap before I start on this.

[GunMetalGrey]

Can confirm that this stuff is shaping up to be quite awesome. 

[HipMF]

More progress.

After figuring out where to run the last two pipes I decided to take it back apart and start welding stuff. My welding isn't pretty but it should be good enough.

Where I left off tonight.

Test fit in the car. It's snug.

I've still have some more welding to do, but I'm pretty happy with how it's shaping up. It was a pretty ambitious project, so I'll be happy when I'm at the point where I can cross "manifold" off the to-do list.  Hopefully I'll have some time this week to make a flange for the downpipe. That will be the next project.