Custom made Exhaust manifold

[happy john]

Would work well Dilmah, You'll need bigger injectors mate.

 

[Rabbid-chop]

http://www.turbos.bwauto.com/afterm...wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&


I was having a play with the match -bot and looks like 375hp at 4000rpm at 30psi, around 500ft/lb from 2500rpm onwards, 250ft/lb and 8psi at 1500, 350lb and 17psi at 2000 rpm.
On the turbine map looks like the first three plots land on a 58mm wheel and a 0.83 A/R.
It does all look a bit optimistic, but you definitely do make more power with less boost when your turbo is efficient.

 

[Rabbid-chop]

Here's one with a possibly more diesel-like volumetric efficiency.
30psi, everything fits on the map quite nicely, looks like the .64 T-housing would be suited. Not 100% sure what im doing though. It would be good to see what someone more tech savvy can come up with.
http://www.turbos.bwauto.com/afterm...wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&


I did one for my ZD30 for around 20psi - fits on the map even better, gets more efficiency islands. Makes me want to get one! I wonder what fueling mods i would need though...
Bloody addictive these match-bot games!

 

[happy john]

ZD is a toy and does the job well for what it is. This is what you need.
https://www.youtube.com/watch?v=9sg...ScsROwNAsSm0JENCRLbA3ZK3OtnXnZBB7Z3_nfpxral9n

 

[abouttogobush]

Here's one with a possibly more diesel-like volumetric efficiency.
30psi, everything fits on the map quite nicely, looks like the .64 T-housing would be suited. Not 100% sure what im doing though. It would be good to see what someone more tech savvy can come up with.
http://www.turbos.bwauto.com/afterm...wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&


I did one for my ZD30 for around 20psi - fits on the map even better, gets more efficiency islands. Makes me want to get one! I wonder what fueling mods i would need though...
Bloody addictive these match-bot games!

fool:*******:

 

[abouttogobush]

ZD is a toy and does the job well for what it is. This is what you need.
https://www.youtube.com/watch?v=9sg...ScsROwNAsSm0JENCRLbA3ZK3OtnXnZBB7Z3_nfpxral9n

 

[user 10312]

That's awesome! It's looks like such a sleeper to.

Here is a link a little more back on topic of a D40 on the American Frontier forum that has had some serious work done to it including a hand fabricated exhaust manifold for a larger turbo.

http://www.clubfrontier.org/forums/f47/project-300-diesel-hp-nearly-done-71347/

 

[happy john]

The comment and link was in jest lol. My 159hp would do a 20-21 if not slower.

 

[Rabbid-chop]

That's awesome! It's looks like such a sleeper to.

Here is a link a little more back on topic of a D40 on the American Frontier forum that has had some serious work done to it including a hand fabricated exhaust manifold for a larger turbo.

http://www.clubfrontier.org/forums/f47/project-300-diesel-hp-nearly-done-71347/

Pretty interesting that he was using a 2860 "disco potato" with great success but not enough oomph down low with the .85 rear. Pretty much confirms the calcs that the efr 6258 with .64 rear would be a madman, as they are pretty much equivalent size, the efr being much faster spooling and more flow too.

 

[Rabbid-chop]

 

[Rabbid-chop]

GTX 2860 has comparable map to EFR6258 but much slower to spool

 

[dilmah]

So I have decided to make a new manifold, I made the mistake of welding the current one backwards and it's thus useless unless I cut the flange off and redo it. I decided to just make a new one as steam pipe and laser cutting is cheap and it was not worth the effort.

I considered making the manifold out of both short and long radius bends




I was going to notch the inner bends instead of using T pieces for better flow but it was too difficult to do in a drill press

Where I am at now. I am TIG welding as much of it as I can as it is good practice



The finished product will be sent to pacemaker in SA for coating before install and testing

 

[dilmah]

Few pics of my welding. I had some good runs but I am only still learning to TIG so its not that good









Just need to finish the last bit of welding amd to weld a bung in for the EGT sensor. Then its off to machining and then to Pacemaker in SA for coating

 

[dilmah]

 

[dilmah]

Finished all of the intake and intercooler piping this week. Got the dump pipe tacked up but I ran out of Argon so I will TIG that over the Easter break.I also remade the intercooler brackets and painted them.

The to do list:
Plumb up oil and water lines, this will require me to custom make the fittings so I will need to wait for laser cutting
Weld in EGT and AFR bungs into dump pipe
Modify Water lines for W2A
Weld in bung for Pre I/C temp sensor





Its a shame you cannot buy adapters for the oil and water drains at a reasonable price, looks like I will be making my own





I am unsure if I will run a manual boost gauge on this setup. I have the MAP sensor installed in the intake manifold so I may just use that. If I run a manual boost gauge I will need to tap a fitting into the cold side of the W2A core

 

[jonney]

you don,t think the inlet pipe to turbo won,t get too hot being stainless steel?,

 

[dilmah]

Nah it wont matter, the intercooler will pull all of the heat out of the compressed air before it enters the engine anyway. I can TIG stainless, Ali is a whole different ball game!

 

[Rabbid-chop]

you don,t think the inlet pipe to turbo won,t get too hot being stainless steel?,

Stainless is a much better "insulator" for want of a better word than mild steel, let alone aluminium, which last time i checked is one of the most heat-conductive materials known to man.

 

[tweak'e]

you don,t think the inlet pipe to turbo won,t get too hot being stainless steel?,

won't make any difference. small surface area with large air flow going through it.

 

[dilmah]

I agree with Tweak'e the runs are very short so there will be no real time for the temperature to dissipate.