Bag-O-Chips Posted October 15, 2011 Report Share Posted October 15, 2011 As it stands, a majority of the SMB Manifolds have failed. My particular unit never cracked at the runners but the waste gate mount itself broke off and left a lemon sized hole in it's place. Since then I've sliced up the SMB manifold (all due respect to SMB) and turned it into a Jig for my Twin scroll manifold. My turbo is a Garrett GT4088R with a Divided .95 A/R turbine housing. I had Flanges Watter-Jetted out for me through FlatOut Gaskets. btw, the Flange, collector, and every pipe in the mix is Schedule 10 304L. 321l was too expensive for my wallet at the moment. Here are some Teaser pics: Cut up for a Jighttp://i118.photobucket.com/albums/o113/solidboosttsi/IMG01093-20111005-1911.jpg Yes, It is 1/2" thick with individual flangeshttp://i118.photobucket.com/albums/o113/solidboosttsi/IMG01114-20111014-1719.jpg Messing with a Box of bends http://i118.photobucket.com/albums/o113/solidboosttsi/IMG01115-20111014-1747.jpg It's gonna be a while before this project is finished, stay tuned! -Chips Link to comment Share on other sites More sharing options...
Chad Posted October 15, 2011 Report Share Posted October 15, 2011 that looks like schedule 5, not 10. What is the wall thickness? 10 is .109", and 5 is .065". it may not sound like a lot, but there is a bid difference in longevity and even performance. Good luck, should be a big learnign experiance, and hopefuly a very rewarding one. Link to comment Share on other sites More sharing options...
25gconquest Posted October 15, 2011 Report Share Posted October 15, 2011 Nice welding it is looking good. Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 15, 2011 Author Report Share Posted October 15, 2011 The Sched 10 is still on the way from Ace Stainless, The tube you see in the pictures are .035" thick 304 That I had laying around. for the mean while, Those are what I'm using for mock up. It's the closest I can get to the actual bends and radii for the pipe I ordered. Mocking up with PVC although inexpensive, just doesn't give me the articulation that I want. I'm trying to minimize the amount of bends yet keep the runner length to a minimum of 16" Link to comment Share on other sites More sharing options...
Lance_S Posted October 15, 2011 Report Share Posted October 15, 2011 Nice welds. Looking good. Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 15, 2011 Author Report Share Posted October 15, 2011 Thanks guys! Link to comment Share on other sites More sharing options...
Chad Posted October 15, 2011 Report Share Posted October 15, 2011 You'll want to mock this up on a block, your number one runner as shown will likely hit the oil filter. Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 15, 2011 Author Report Share Posted October 15, 2011 i've got the #1 runner issue sorted out, It'll take some really tight radius 90's though. Also I've found a smaller filter from Lancer Evo's It should help slightly with the clearance issue. Genuine Mitsubishi Part # MZ690116 Link to comment Share on other sites More sharing options...
Technology Posted October 16, 2011 Report Share Posted October 16, 2011 Or use a remote filter. Link to comment Share on other sites More sharing options...
Indiana Posted October 16, 2011 Report Share Posted October 16, 2011 (edited) I'd build it to mount upside down Is that a twin scroll collector? http://www.turbobyga...bo_tech102.html Edited October 16, 2011 by Indiana Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 16, 2011 Author Report Share Posted October 16, 2011 Yup, It's a divorced collector, 2 cylinders per volute. obviously 1-4 and 3-2. I like the ease of a top mount, not to mention I'm trying to keep the pipe length at a minimum. The GT4088R spooled up pretty fast with the SMB header on a 4-1 collector set up. With the .95 a/r housing I'm trying to spool as soon as possible so the runner length is being kept short. Indiana - the reason for not going bottom mount is the clearance issue. The GT4088R is a Massive turbo. It is cramped up with the oil filter and oil cooler lines where they are already. Link to comment Share on other sites More sharing options...
Starwolf Posted October 16, 2011 Report Share Posted October 16, 2011 Curious what rpm you see full boost at. Turbo looks awesome Link to comment Share on other sites More sharing options...
Chad Posted October 16, 2011 Report Share Posted October 16, 2011 This is a "devided - equal length - tuned length" model to give you some inspiration. It takes a lot of bends to make one fit with the lenght of the collector entry so low in the engine bay. the total exhaust path on this is 30" head to turbine. http://webpages.charter.net/catsamuel/DCP01020.JPG Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 16, 2011 Author Report Share Posted October 16, 2011 I think I remember when you were making that manifold a few years ago! 30" is a little too long for my liking. I chose 16" for a sake of keeping as much heat and exhaust velocity going into the volutes of the turbine. My setup is focused mainly on the upper RPM range, and with the 4.62 gear set that I got from StarquestRescue, I'm pretty much always up there. Don't laugh when i mention this but.... cruising at 60 mph i'm around 5k rpm in 5th Link to comment Share on other sites More sharing options...
Starwolf Posted October 16, 2011 Report Share Posted October 16, 2011 LOL wow....hope the car is fast all the way up to 80mph hehe What is your top speed now? Link to comment Share on other sites More sharing options...
Chad Posted October 16, 2011 Report Share Posted October 16, 2011 tuned length are specifically suites to engines that stay at a narrow rpm band. below that band, they do loose some power, bt when the enter their tuned sweet spot, everything comes into alignment and they really perform. mine are tuned for 65OO rpm peaks. What you are doing will work just fine, I'm just throwing ideas out there. I have another design with 23" runners, but it takes up just as much space because of its 2" runners. It looks very different, it was designed for a very large frame 72 mm turbo. I look forward to seeing what you come up with on that twisted orientation turbo flange, I've thought about doing that, just never tried it. Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 16, 2011 Author Report Share Posted October 16, 2011 Thanks Chad, it means alot coming from a seasoned SQ Veteran. Your ideas have been considered long before I tried building this hahaha... let's just say I'm taking your ideas (bits and peices) and implementing them into the design of the manifold. Although The tuned runners are definately considered in the build, They're just on the short side of the design. I had a total of 8 invidual flanges cut out for me 4 for the short runner manifold and the other 4 for the Turbo relocation Under the passenger side headlight that blows directly into the intercooler. I'm also experimenting with venting the BOV into the exhaust as well as a Crank case evac into the down pipe. Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 16, 2011 Author Report Share Posted October 16, 2011 Starwolf - I top out at 120ish @ 6500 in 5th. But I get there pretty damn fast and the Rev limiter pegs! if I stretch it to 8000 like Schneider states...(so they say the valve spring and Ti lock/retainer combo will) i should be able to hit 135 or so. Kinda dumb but I like feeling torque press my heart against my spine. Link to comment Share on other sites More sharing options...
Chad Posted October 17, 2011 Report Share Posted October 17, 2011 I had to come up with an unusual collector design to make my turbo sit low like I wanted it. First I decided on the flange location, then built the runners to suit [just like you are]. It's a 4 into 2 design. I modeled it in mild steel, but have since made 2 out of Inconel. http://webpages.charter.net/catsamuel/P8260052-r.JPG http://webpages.charter.net/catsamuel/P8260054-r.JPG http://webpages.charter.net/catsamuel/P8270059-r.JPG http://webpages.charter.net/catsamuel/P8270060-r.JPG http://webpages.charter.net/catsamuel/P8270061-r.JPG Link to comment Share on other sites More sharing options...
Indiana Posted October 17, 2011 Report Share Posted October 17, 2011 Garrett gives the overall dimension specs for a GT40 of about 6" across and 8" wide which isn't any bigger than this larger 20G mitsubishi housing shown here and there's plenty of room for the oil filter that angle is a little misleading as shown There's 4 bends per runner with a stub off the flange to push it further from the head but that could have just was easily been a stub bend. When you use these bends you can pretty much aim them where ever you like. I don't know the exact lenght of each bend but I'd guess its about 4" so you have about 20" from the head to the turbine housing and that's not "long" at all. If you want it more forward then configure the runners like Chad showedhttp://www.b2600turbo.com/images/headerup%20030.jpg this one was originally planned for an external WG in that short straight section off #4 but this just shows you can reposition the same number of bends as in the header shown above here just reconfigure the bends. They are really like Legos, you can build this over and over just tape it together and get an idea what you want. If you get tubing bends once you cut them you are stuck with them or throw them away and start over. You will NOT have these bends crack. Its been over 5 years now and not one crack or warp on any of them. The bends are much thicker than tubing and when coated and wrapped its easy to retain the heat so it can all reach the turbine housing. They are stainless and will not rust internally like a mild steel tube can and I'd not make an exhaust header or intercooler tube out of mild steel again if you gave it to me and paid for the engine because sooner or later they will rust and that crap blow right into your cylinders or turbine wheel. -garbage http://www.b2600turbo.com/BE1/IM002880.JPG Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 17, 2011 Author Report Share Posted October 17, 2011 you guys are giving me more ideas for the 2nd header i build Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 18, 2011 Author Report Share Posted October 18, 2011 waiting on materials... argh!!! Link to comment Share on other sites More sharing options...
ucw458 Posted October 19, 2011 Report Share Posted October 19, 2011 waiting on materials... argh!!! I can drive to ace stainless and pick up whatever I need. No waiting Link to comment Share on other sites More sharing options...
BOHO Posted October 19, 2011 Report Share Posted October 19, 2011 What did you do for your "box of bends" ......I was thinking of playing with one for my 1jz.....I only have a mig welder though. Link to comment Share on other sites More sharing options...
Bag-O-Chips Posted October 19, 2011 Author Report Share Posted October 19, 2011 I can drive to ace stainless and pick up whatever I need. No waiting you're +1 on me lol The weather here is a steady rainy 42 degrees too.... fml Link to comment Share on other sites More sharing options...
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