Chad Posted November 21, 2006 Report Share Posted November 21, 2006 Equal lenght tubes : within 3%, 321 SS, 16 gage walls, large 3" radius mandrel bends, 1-3/4" OD tubes. "Burns Stainless" turbo double-slip collector. Runner lenghts determined by Burns Stainless X-design software for a power peak at 6000 RPM and a redline of 7000. http://webpages.charter.net/catsamuel/DCP01023.JPG http://webpages.charter.net/catsamuel/DCP01016.JPGhttp://webpages.charter.net/catsamuel/DCP01017.JPGhttp://webpages.charter.net/catsamuel/DCP01018.JPGhttp://webpages.charter.net/catsamuel/DCP01019.JPGhttp://webpages.charter.net/catsamuel/DCP01020.JPGhttp://webpages.charter.net/catsamuel/DCP01021.JPGhttp://webpages.charter.net/catsamuel/DCP01022.JPGhttp://webpages.charter.net/catsamuel/DCP01023.JPG Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 Almost forgot, while this model is a combined collector, the tube locations are optimized for true split pulse devided housings. This is for those with devided turbine housings. This technology is proven to increase lower boost efficency, and will decrease lag by 15% according to Garrett. Link to comment Share on other sites More sharing options...
emagdnim Posted November 21, 2006 Report Share Posted November 21, 2006 oh my.... :wink: Link to comment Share on other sites More sharing options...
Questsi Posted November 21, 2006 Report Share Posted November 21, 2006 you beat me to it GREAT JOB Chad!! I can't wait to sit the GT35 on that bad boy 8) Link to comment Share on other sites More sharing options...
eeaston Posted November 21, 2006 Report Share Posted November 21, 2006 Wow, that's nice work! And very expensive work. I've priced 321 and Burns collectors and they're not cheap. Looking forward to seeing a dyno sheet! Link to comment Share on other sites More sharing options...
substock Posted November 21, 2006 Report Share Posted November 21, 2006 thats awesome, and scary also. Questsi PostPosted: November 20, 2006, 9:36 pm Post subject:you beat me to it Very Happy GREAT JOB Chad!! I can't wait to sit the GT35 on that bad boy Cool you'll definatly need to take some pics of how that bad boy looks installed Link to comment Share on other sites More sharing options...
YELLOWHELL Posted November 21, 2006 Report Share Posted November 21, 2006 AWESOME! Chad, You are consistantly contributing to the community and it is appreciated. Link to comment Share on other sites More sharing options...
shift1313 Posted November 21, 2006 Report Share Posted November 21, 2006 how the heck do you weld those 4 pipes at the collector? That thing is a work of art. I would like to hang it on my fridge Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 awsome job man but i see a couple of problems that are bugging me. looks like you have to relocate the oil filter or bake it to nothing It's close, but not that close. If that's the biggest problem, well that's OK with me :wink: A relocation kit or some heat shielding will do the job. Ond of the goals was to be able to use the stock filter in the stock locatin for easy oil changes. If you notice, you can even keep the ABS. All the has to relocate is the PS resivior and vac canister, both easy moves. http://webpages.charter.net/catsamuel/DCP00910.JPGhttp://webpages.charter.net/catsamuel/DCP00911.JPG the biggest problem i see is a down pipe. lots of pipe back there and not much room for a down pipe. test fit it in a car yet so we can see any clearance issues? its look great but just wondering how you plan to get the exhaust out of the turbo. yes, it will require a new downpipe/modification, but the design specs was to accomidate a 4" DP, it will ... http://webpages.charter.net/catsamuel/DCP00913.JPG A lot of time went into pipe locations, not just their lenghts. It requires no modification to fit besides the relocation of the afore mentiond items, and some heat shielidng of some lines. BTW, these pics are of the mild steel prototype I usd to figure out the angles. The real pipes are all ground 100% flush for a gap-free weld. Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 how the heck do you weld those 4 pipes at the collector? That thing is a work of art. I would like to hang it on my fridge Not to give away all my tricks, but it requires assembly, some welding, disassembly, more welding, and reassembly. I buy the collector itself form burns to save on time, they can make it cheaper than I could because they make these all day long, and have better tooling than I do. Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 Wow, that's nice work! And very expensive work. I've priced 321 and Burns collectors and they're not cheap. Looking forward to seeing a dyno sheet! Just the raw materials are a tad over $770, and that is with a bulk purchase discount. It takes 10 U bends :shock: with only 1/2 a bend left over. It was asked by another member in a PM, how much? It's about $1100 give or take. I doubt I'll be selling many so I haven't realy decided. I just made it for a friend, (and 1 for myself). I'll be making another identical one, and another veriosn in 2" OD 20 gage 625 inconel for a different friend (and 1 for myself). It will be a different design for the different diameter tubing. For about $1500, I doubt that will be a big seller either :wink: but again, I'm making it for myself, so I'll offer it to others. I purchased enough Inconel to make ~6 of them, gotta love Ebay ! Link to comment Share on other sites More sharing options...
soulja620 Posted November 21, 2006 Report Share Posted November 21, 2006 :shock: Link to comment Share on other sites More sharing options...
emagdnim Posted November 21, 2006 Report Share Posted November 21, 2006 very nice man. it almost seems like the down pipe may have to swing out to the right of the car a bit to clear everything but i could be wrong on that. whats the total dimentins of that thing? I am looking into making a larger powder coating oven and i should be able to do a good heat coating on somehting that size. so far im designing it large enough to heat 2 of the rear swing arms for our cars and the rear end front cross peice. let me know soon so that I can acomodate my oven for the size of that artwork of yours awsome work man UMMMM... no. you can't powdercoat a manifold, unless you have an "oven" that can heat at about 2000 degrees. otherwise you'll have a nice melted mess. Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 turbo headders in this category (race setups) reach ~1400 in the metal itself, with EGT's of up to 1800*. This is why I used 321 stainless, it's capable of tolerating that temp range. In turbo headders above 15 PSI, if it's not glowing, you aren't runnign the right air/fuel mixture :wink: . Your temp ranges are quite accurate for NA alications, and those cotings work well for them. I've heard of those cotatings burning off of a turbo headder in just a few hours. Link to comment Share on other sites More sharing options...
artinist Posted November 21, 2006 Report Share Posted November 21, 2006 admins, change chads username to michaelangelo I am antimpower and I approve this header Link to comment Share on other sites More sharing options...
TopDawg_43 Posted November 21, 2006 Report Share Posted November 21, 2006 Everytime I think you can not get any better, you go and out do yourself!! GREAT JOB Chad!!!!! Link to comment Share on other sites More sharing options...
Richie_Rich Posted November 21, 2006 Report Share Posted November 21, 2006 Daaaaaam. That is some nice work. That's one of those...If I has $1,100 laying around, I'd be ordering. Great job. Link to comment Share on other sites More sharing options...
importwarrior Posted November 21, 2006 Report Share Posted November 21, 2006 another work of art... chad i need you to finish your car and run it on the dyno and track. i want to see what kind of performance you make! Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 I may be taking it in for a dyno run-tuning this winter since I got the trans all sorted out finaly. I have an almost identical headder on my car already, one that I made ~4 years ago. Lets just say I already know first hand that this design works VERY well My T-4 is capable of ~550 HP and I can fully spool it by 3500 withi this design. I only have a T-4 with the 62-1 compressor at the moment, but I pulled a 109 MPH trap at only 15 PSI, and this is with stalling off the line and having to restart :oops: (a mere 16.9 ET), If I haden't stalled, the trap would have been more like 115. This was my very first track run so I wan't prepared for how the tires were going to react to the track surface. Using ths formula : Calculate HP From MPH and Weight HP = (((MPH / 234)^3) * Weight) This formula gives a fairly accurate idea of actual HP (to the ground) based on Trap speed and weight. In all circumstances trap speed is a direct indication of how much HP the car makes given its weight. (((109 / 234)^3) * 3050 = 308.6 this is ~308 RWHP at 15 PSI, so running ~30 psi is in the upper 400's, maybe a low 500. I tried a 20 PSI run after that, but destroyed the driveine at about the 40' mark which prompted the T56 kit. The highest boost I've run so far is 24, and it was danm scary, I need a safer place to tune with that much power :wink: . When I make the Inconel headder in a few months, I'm upgrading to a GT42R and hope for high 600's. The only reason I haven't done a dyno before is because the nearest one is ~100 miles away. I'm expeting Ivan to break into the low-mid 600's with this this headder upgrade alone running the same boost and timing as the setup that made 570. Link to comment Share on other sites More sharing options...
soulja620 Posted November 21, 2006 Report Share Posted November 21, 2006 When I make the Inconel headder in a few months, I'm upgrading to a GT42R and hope for high 600's. The only reason I haven't done a dyno before is because the nearest one is ~100 miles away. I'm expeting Ivan to break into the low-mid 600's with this this headder upgrade alone running the same boost and timing as the setup that made 570. :shock: :shock: :shock: :twisted: Link to comment Share on other sites More sharing options...
JustPaus_88TSi Posted November 21, 2006 Report Share Posted November 21, 2006 That's just silly! Realistically speaking Chad, what kind of life span could the Inconel header have? Link to comment Share on other sites More sharing options...
heefner Posted November 21, 2006 Report Share Posted November 21, 2006 Wow, that looks awesome! I have 2 questions, will the compressor fit under the hood and are there provisions for a wastegate? Link to comment Share on other sites More sharing options...
Questsi Posted November 21, 2006 Report Share Posted November 21, 2006 Wow, that looks awesome! I have 2 questions, will the compressor fit under the hood and are there provisions for a wastegate? It fits under the hood and there will be a wastegate. Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 Wow, that looks awesome! I have 2 questions, will the compressor fit under the hood and are there provisions for a wastegate? http://webpages.charter.net/catsamuel/DCP00910.JPG It sits about 1/2" higher than the oil cap, about flush with the strut isolator tops. The compressor shown is the biggest you can get (4" inlet 2.5" outlet)without going to the 1000 HP class turbos like a GT42 +. When I build the GT42 headder, it will require a different collector design as the compresor is a lot larger OD than this one. Link to comment Share on other sites More sharing options...
Chad Posted November 21, 2006 Author Report Share Posted November 21, 2006 In theory, inconel will last forever, it's got an "opperational" temp range of ~1800* F and can withstand up to 2100* F intermitantly. Froms Burns stainless webiste : 625 Inconel, containing approximately 60% Nickel and 22% Chromium, was developed to cope with the extreme heat and strength demands of jet engines. Molybdenum and Niobium elements also contribute to 625’s strength at temperatures greater than 1800º F, where 321 SS is unsuitable.Inconel 625 excels in applications such as Rotary engines and extreme duty turbocharger exhausts "the main benifit is that it retains over 75% of its room temperature strength at 1200*F (which is a normal service temp for our cars). This alloy also exhibits high creep and rupture strength; outstanding fatigue and thermal-fatigue strength racing teams have utilized Inconel for producing ultra-light, high-durability exhaust headers" This 625 alloy is the best material for a headder that is currently avaialble. 625 and it earlier alloys of 718 are what get used for most rocket and turbine engine parts. Link to comment Share on other sites More sharing options...
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