Exhausts

Hi All,

Just thought I'd share a few things I've been working on recently.

First up is an exhaust manifold with the turbo flange an additional 30mm away from the engine, but in the same orientation to aid clearance against the engine / bell housing when fitting large a turbo.

CAD design, jig and tacked together part.



I've also made the jig to suit standard exhausts.



I plan to put a brace inbetween the exhaust flange and the turbo flange to help support the turbo and so reduce the risk of cracking



The jig has a small hole in the turbo flange mount so I can purge the exhaust when fully welding it.



The manifold will also have a external wastegate with the pipe coming off the side above the turbo flange, which I'll cut in after



I've also drawn up all parts including a jig for a 3" elbow and started looking at the flow through them.



Cheers

Looks really good mate, well done!
I wouldn't fancy drawing that manifold up in Solidworks or Inventor, that's for sure!!!!

mike74 wrote:Looks really good mate, well done!
I wouldn't fancy drawing that manifold up in Solidworks or Inventor, that's for sure!!!!

Thanks for the compliment!

Haha I'm a bit sad and love doing exhaust headers and rollcage work etc in solidworks, its not too bad once you've done a few

I really wish I could see these pictures

TBH I don't have to do anything using 3D sketches at work so haven't learned how to do them properly. Looks like a proper ball ache regardless!

Mate this looks awesome, well done

That's cool progress.
Wish I was good with cad drawing software, makes me angry when see how easily some people draw these cad images .
I'm struggling with sketchup and generally use my own style CAD , Cardboard Aided Design .
Good luck with your manifold and elbow designs .

Ryaneg6freak wrote:I really wish I could see these pictures

Yeah I don't see them either looks like they are on photobucket

That looks like a really nice manifold,the external wastegate will need to be at collectors,most manifold have it pointing towards the comp housing.would be interested in this manifold if you every want to do a batch of them.


Zia

I don’t see them

Please god, no more photobucket hosting! Use the forum uploader lol.

I can't see them either....

Sorry it was dodgy photobucket upload, I've been going off that site for a while now so good excuse to try postimage out!

Hopefully the pics below work... yes the external wastegate will come out just above the turbo flange towards the compressor, I would love to have it pointing downwards slightly to help the flow but just don't think there'll be room.

I could be tempted to make more if requested, but I've got a few other jobs to complete first...









Thanks for all the nice comments so far as well (for those that have been able to see the pics)

Great work

Mr B wrote:That's cool progress.
Wish I was good with cad drawing software, makes me angry when see how easily some people draw these cad images .
I'm struggling with sketchup and generally use my own style CAD , Cardboard Aided Design .
Good luck with your manifold and elbow designs .

Nothing wrong with abit of Cardboard Aided Design! It's still the best way to prove something out!

Yea, I still got nothing lmao

^ move out of the desert lol . Must be a pain these days with that sort of data limits .

Very nice work so far

Mr B wrote:^ move out of the desert lol . Must be a pain these days with that sort of data limits .

You have no idea. Thing is I can see Flickr pictures though, and ones uploaded by the forum, just not photobucket and others

Great work & development - looks excellent - hope the finished product works well for you !

What size pipework and material and size of the elbow ?

nomad wrote:What size pipework and material and size of the elbow ?

The manifold is 1.5" nominal bore with 2.8mm wall, all the flanges are 10mm and all 316l stainless.

The elbow is 3" od 1.6mm wall 316l again with 10mm flanges

Nice bit of CFD analysis there. At Cummins our analysis dept do this too, for exhaust manifolds they would also do some thermal fatigue analysis to show if there's potential for cracks at the welds,

Old thread but any more news on the above? Would be interested in these next year especially elbow

On another subject I emailed mongoose about new exhaust and they e stopped making them all together so where can you get a loud exhaust from now??

Powerflow or similar i think are the only options now. Fwiw i was 520 for a 3" exhaust from the elbow back. Just had its yearly inspection and they added an additional hanger to stop it vibrating against the front ARB...free gratis too!