Shop Life 2.0

[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.

[B C]

Great work, Mike! 

Im enjoying these updates

[HipMF]

snap said:

Great work, Mike! 

Im enjoying these updates

Thanks. The goal is to have the car running by April. It's hard to believe the engine has been out of the car for 7 weeks already, so if anything I'm probably a little behind schedule. The header is obviously the most complicated and difficult part as far as fabrication is considered, so hopefully things will start to come together faster after I get the exhaust sorted out.

I'm also planning to build a legit ECU harness from scratch, so that will take some time. Sustained progress will be the key to meeting my self-imposed deadline, so you can look forward to weekly updates until spring.

[m42b32]

That looks great!!

[Jdesign]

Nice Update!

[HipMF]

Thanks @patsbimmer1 for getting me nice discount on a big box of stuff from ECS.

Didn't accomplish much this weekend, but the manifold is nearly done. I just need to get a longer burr to clean up some of the welds inside the collector.

My intercooler also arrived, so if making a downpipe isn't enough to keep me busy, I can try to figure out how to get that mounted up.

[Jdesign]

HipMF said:

My intercooler also arrived, so if making a downpipe isn't enough to keep me busy, I can try to figure out how to get that mounted up.

What is this out of? It looks like a F30/32 intercooler?

[patsbimmer1]

That manifold is looking great!

[suspenceful]

Jdesign said:

What is this out of? It looks like a F30/32 intercooler?

I'm also curious...

I have a stock N54 intercooler that I would've parted with.

[HipMF]

Jdesign said:

What is this out of? It looks like a F30/32 intercooler?

suspenceful said:

I'm also curious...

I have a stock N54 intercooler that I would've parted with.

It's from an ecoboost mustang.

An N54 intercooler is twice as thick. I might have used one, but I wanted something with normal slip-fit connections instead of the weird clippy things that BMW uses.