[Mk2] [Turbo] Homebrew topmount manifold finished!

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mark239
Posts: 690
Joined: Sun Feb 25, 2007 8:31 pm

[Mk2] [Turbo] Homebrew topmount manifold finished!

Post by mark239 »

Finished my ghetto manifold at last!

I took it upon myself to make my own manifold from a cheap ebay job (300 quid) and a flange. I didnt fancy paying a grand for one from the states, and waiting 3 months to get it.

I started with this

http://cgi.ebay.com/ebaymotors/JDM-3SGT ... ccessories

welded on a flange

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Another view of adapter plate on to suit my GT35, and smooth out the inside of the pipes leading up to the turbo

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Next, I got myself this 60mm wastegate from GS Racing (A few people I know have been using them for a while)

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And needed to make it fit - so I had to cut the old wastegate tubes off and weld in wider diameter piping and this is the result - not too bad if I do say so myself. Spent an age getting nice smooth lines inside the pipework. You can also see the spacer plate I had to have milled (Only bit I didnt do myself!)

The red arrows in the diagram below show the bit I had to physically make in order to make the 60mm wastegate fit - it was originally designed for a 40 something mm wastegate which I decided would be too small (You can see it the way it used to be in the pictures above). You would not believe how long it took to get the angles right on that damn thing. More than one time I was for throwing the lot in the skip and forgetting about it..

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Now all I have to do is weld the wastegate flange on so it sits at this angle to clear the firewall, and I have me a top mount manifold!

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Am going to be bracing it all up well so it hopefully lasts some time between cracking.

Finished it completely over the past few days:

Finally got round to welding up that last bit of manifold. Took next week off work to hopefully finish the lot.

few pictures of the finished article (Red lines show areas that I had to make)

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some slight porting was required to match the gasket
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side view
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steve b
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Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by steve b »

Good work :thumleft:
'02 VX220 2.2 n/a Daily driver - Exige Size TD 1.2 - TAT shorty Diffuser - HardTop - Chris Tullet 4-1 Manifold.

'97 mk1 Mazda Eunos Turbo track car with 260bhp/ton - soon more as Chris Wilsons going to build me an engine over the winter :o) .
cantfindausername
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Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by cantfindausername »

Nice work. You might want some expansion slots in the manifold flange though. Look at the stock manifold, how its flange is 2 pieces.
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jimGTS
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Location: North Kent

Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by jimGTS »

heres my old school apexi top mount for comparison...
smaller tho, lol.


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Dangerous
Posts: 521
Joined: Wed Jan 12, 2005 4:40 pm
Location: Hinckley

Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by Dangerous »

Hey i managed to get a pheonix power manifold off salamanzer's car and it looks VERY similar..the wastegate pipes are slightly different.. however mine has lots of bracing between the runners etc....its has still cracked berfore though as it has several repairs on it.....i defo think it would be a good idea to do the same on yours.. :thumleft:
mark239
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Joined: Sun Feb 25, 2007 8:31 pm

Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by mark239 »

dont worry, it will be well braced up! Im fabbing up a brace across the top, and one to support the wastegate. and the downpipe is also shock absorbed.
mk2too
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Joined: Mon Jan 12, 2009 12:58 pm
Location: braintree, essex

Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by mk2too »

That pipework looks like a peice of art!

Top job!
JJ
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Joined: Tue Dec 14, 2004 9:11 am
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Re: [Mk2] [Turbo] Homebrew topmount manifold finished!

Post by JJ »

Very good !! :thumleft:

If any tip before you fit it... the weld is really neat across the turbo inlet flange... where all 4 join into the flange for the turbo. See if you can apply more weld to it for strengthening or weld in some additional bracing.

Due to the characteristics of our engines rocking back and fourth, this creates stress / stress cracks at the flange weld due to the weight of the turbocharger.. and also if you've a rigid downpipe.

I have a HKS tubular on mine and I've pulled it off 3 times now for reweld.. and this ones braced up pretty good too ! :-k
|| S256SX Airwerks Powered MR2 Turbo || V10 BMW M5 ||
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