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Old 09-06-2012, 11:25 PM   #4676
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In the following pics, you can see where Justin is extending the ends of the jig out to the discharge ends of the manifolds. The v-band inserts are welded on there and this creates with the above description the beginning and the end of the jig for this side. (drivers)

After everything is re-enforced on the jig, we remove the manifold and outlet pipe and then bolt the new flange on and start filling the gaps....

Again, this being the drivers side, we have to consider the steering shaft into the fit. So, all the filler pieces are tack welded and then we'll test fit it all prior to finish welding it... Then Justin will build the merge collector and I'm still not sure of that process so more on that later... He did mention it wont be a hammered into shape collector...
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Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-06-2012, 11:26 PM   #4677
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I'm curious... I'm going to find another set of those around the shop and see if that area that looks like it swelled out actually did... Glowing red to white hot and that much back pressure... It may just be the casting design but we'll see... Maybe someone can come in and state if theirs look like that or if that is deformed...
Here's some photos of my stock exhaust manifolds, for what it's worth.
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Old 09-06-2012, 11:29 PM   #4678
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Here's some photos of my stock exhaust manifolds, for what it's worth.
Well it doesn't look mine are deformed then. They do appear to have been a lot hotter than yours...

Mine had a total of 23 K miles, and yours prior to the header install???

Thanks for Posting those Justin.... the other Justin...
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-06-2012, 11:39 PM   #4679
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I did the header install at the end of December, 2010. I think I was somewhere around 20k miles, maybe less.

The only documentation I have close to that was April 1st of 2011 and I had 24,661 miles on it. So, I imagine I've been putting on average 1k miles on the car a month.
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Old 09-07-2012, 12:04 AM   #4680
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I did the header install at the end of December, 2010. I think I was somewhere around 20k miles, maybe less.

The only documentation I have close to that was April 1st of 2011 and I had 24,661 miles on it. So, I imagine I've been putting on average 1k miles on the car a month.
Crap, I wish I was doing 1K a month....
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-07-2012, 12:07 AM   #4681
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Crap, I wish I was doing 1K a month....
No kidding...mine's from a different side though. I've got just under 46,000 on mine...doing somewhere between 1,600 and 1,800 a month. Then I have occasional months like last month when I put about 4,800 on it
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Old 09-07-2012, 12:12 AM   #4682
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No kidding...mine's from a different side though. I've got just under 46,000 on mine...doing somewhere between 1,600 and 1,800 a month. Then I have occasional months like last month when I put about 4,800 on it
and you enjoyed every mile of it except for when
Chris was glaring at you...
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-07-2012, 12:14 AM   #4683
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and you enjoyed every mile of it except for when
Chris was glaring at you...


Not my fault....

...Just like when old man John kicked up the rock and cracked my windshield....if I hadn't been following so closely, it wouldn't have happened, and there was nothing he or I could've done to change the outcome. Same applies here...
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Old 09-07-2012, 12:16 AM   #4684
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Not my fault....

...Just like when old man John kicked up the rock and cracked my windshield....if I hadn't been following so closely, it wouldn't have happened, and there was nothing he or I could've done to change the outcome. Same applies here...
Bro, I understand, just ask Kyle...
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-07-2012, 12:17 AM   #4685
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Bro, I understand, just ask Kyle...
You mean the story about you digging up the asphalt?
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Old 09-07-2012, 12:20 AM   #4686
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I think you ninja edited this...




lol, we are in the process of building manifolds from scratch... We got one of the jigs mostly finished today... Tomorrow we start fabbing the actual manifolds... When we get on e tack welded together and check it for fit, then we'll carry on with the other one...

Stay tuned



Still tuned in???

Ok, we got some scrap steel pieces and started building the jigs. We'll build both sides off the main base...

While Justin pictured below, a very capable and talented fabricator, was prepping some pieces, I marked, drilled and tapped the main base for the new flanges...

Justin drilled and tapped the side piece of which there will be two.. He used countersunk bolts so that the alignment will always be exact...

Here in these pics, you can see the manifold bolted to the base and one of the side pieces on it... We have the v-band clamps and the centering pieces in place... The next item is to build up and out from here to create the end points and alignment pieces for the turbo end...

I didn't understand the process at first due to never having done any of this kind of fabrication.... Now that I see it, it's making sense... I still can't do this but that's ok, Justin and Corey both can...

As for obstructions, nope, nothing other than the designed narrowing of the manifolds... bear in mind we are blowing a high bred 427 cubic inches of exhaust through a manifold designed for a more sedate 376 cubic inch engine.

We knew the manifolds were going to be the biggest restriction but I wasn't sure of the degree of it... These handmade manifolds were discussed when
I first met Corey, but we held off until we had some miles on the motor and everything else sorted out... We are still trying to get some things (fuel system...aeromotive frigg'in pump) sorted out, but we have a plan for that as well... Think Weldon pump with a pulse modulated speed controller and a sump/surge system.... but back to the manifolds...

When completed and test fitted on the car, we will then remove them and have them ceramic coated... and yes, it is a heavy wall stainless steel tubing being used....There will be no restrictions....

And yes, there is a bit more than heat discoloration... they are flat smoked... burned... torched.... seasoned... or any other descriptor you can apply to over heated and stressed cast iron manifolds...
Okay i actually read before i posted this time, them boys sure look like they know what the hell they are doing, beyond my fabrication skills for sure!
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Old 09-07-2012, 12:22 AM   #4687
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You mean the story about you digging up the asphalt?
yup...

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Okay i actually read before i posted this time, them boys sure look like they know what the hell they are doing, beyond my fabrication skills for sure!
oh no... and here I was crapping in your thread... Hey Mike and Justin and PQ and others, party in FarthestNorth's thread....
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-07-2012, 12:26 AM   #4688
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yup...

oh no... and here I was crapping in your thread... Hey Mike and Justin and PQ and others, party in FarthestNorth's thread....
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Old 09-07-2012, 12:33 AM   #4689
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where'd ya go....
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-07-2012, 12:37 AM   #4690
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where'd ya go....

The party duhhhhhh
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Old 09-07-2012, 12:41 AM   #4691
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The party duhhhhhh
LOL, I earned that one
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If the car feels like it is on rails, you are probably driving too slow. -Ross Bentley

Horsepower is how fast you hit the wall.
Torque is how far you take the wall with you.

“If everything seems under control, you're just not going fast enough.” Mario Andretti

If you can turn, you ain't going fast enough...
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Old 09-07-2012, 12:42 AM   #4692
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LOL, I earned that one
I get to sneak one in here and there...

...dude....read your PM's....
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