I'm modding a trick cast manifold for 50mm! Pics inside.
05-04-2014, 10:14 PM
#1
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I'm modding a trick cast manifold for 50mm wastegate! Pics inside.
As far as I know, I'm the only person to do this so far. I don't even know of anybody who is using the front wastegate port on theirs so check this out.
I didn't like the idea of running the waste gate on the cross over pipe under the truck, just seems really backwards and not the most efficient for flow. Sure, it works, but I would rather be truly bleeding exhaust from all 8 cylinders.
I started by cutting the built in flange off. This took forever with a sawzall on stainless. I probably have a solid hour of cutting time to get through this.
Finally.
Then opened up the hole from 1.5" to 2" for the 50mm waste gate. The built in flange is for 38mm.
Test fit of new 2" waste gate pipe.
And here is the full length tube tig welded in. This will be cut down once I get the wastegate and down pipe completed.
Not bad for 20 minutes of experience in tig welding!
The waste gate will be V-band mounted straight off the manifold and then exit 90* out to the wheel, wrapping around the A/C line (heat wrapped of course) and then bend into the down pipe. The heater lines will also be rerouted, which is required no matter what. Again, this is not the final length, it will be cut accordingly.
I'll post more progress as I get there.
I didn't like the idea of running the waste gate on the cross over pipe under the truck, just seems really backwards and not the most efficient for flow. Sure, it works, but I would rather be truly bleeding exhaust from all 8 cylinders.
I started by cutting the built in flange off. This took forever with a sawzall on stainless. I probably have a solid hour of cutting time to get through this.
Finally.
Then opened up the hole from 1.5" to 2" for the 50mm waste gate. The built in flange is for 38mm.
Test fit of new 2" waste gate pipe.
And here is the full length tube tig welded in. This will be cut down once I get the wastegate and down pipe completed.
Not bad for 20 minutes of experience in tig welding!
The waste gate will be V-band mounted straight off the manifold and then exit 90* out to the wheel, wrapping around the A/C line (heat wrapped of course) and then bend into the down pipe. The heater lines will also be rerouted, which is required no matter what. Again, this is not the final length, it will be cut accordingly.
I'll post more progress as I get there.
Last edited by cpolaris502; 05-05-2014 at 09:26 PM.
05-05-2014, 10:04 AM
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I thought about doing that too but you're still forcing all your waste exhaust through that little 38mm hole. The smallest part is still going to be your restriction.
Pretend you drilled a 1/16" hole into a plastic bottle cap and try to blow through it. It doesn't matter what's on the other side of the hole, you can only get so much air through there.
Pretend you drilled a 1/16" hole into a plastic bottle cap and try to blow through it. It doesn't matter what's on the other side of the hole, you can only get so much air through there.
05-05-2014, 10:37 AM
#6
38 to 44 isnt a huge difference, i plan on taking some material out of that casting anyway to open it up. I just didnt want to deal with cutting it all out and welding it all up.
With my setup i could prob get away with a 38mm gate, but i got a smoking deal on the 44mm
With my setup i could prob get away with a 38mm gate, but i got a smoking deal on the 44mm
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05-05-2014, 10:55 AM
#8
im with you i dont really like the idea of the WG in the x-over pipe. Im just doing a quick 90 elbow off my manifold. worse comes to worse and it doesnt work out its not hard to pull the manifold and cut it up like you did. I have a carbite tool that should be able to smooth out and open up that 38mm to slightly larger port
05-05-2014, 03:41 PM
#10
The hole is not the smallest part.
There's a valve in the way.
So a 39mm hole adapted to a 46mm gate.
The gate is the restriction not the hole.
Might measure that hole I think it's larger then 38mm.
Sure looks like a lot of work to fix something that wasn't broke.
There's a valve in the way.
So a 39mm hole adapted to a 46mm gate.
The gate is the restriction not the hole.
Might measure that hole I think it's larger then 38mm.
Sure looks like a lot of work to fix something that wasn't broke.