collectors, lets see yours,ect
 

i will be attempting to make a collector tom. so can i see some pics of ones
you guys made,i will probably do it with a chop saw, i searched and found some post about it,
but not many pics. also any helpful tips.
thanks

Re: collectors, lets see yours,ect
 

anyone? what do you guys think of a boxed style collector like this?
http://www.sdsefi.com/techheader.htm

bash away, but really would it flow that bad?

Re: collectors, lets see yours,ect
 

for the amount of effort involved I guess it's not that bad, I'd be dammed if I could say for sure, that you would be able to get in a car, drive it, and immediately be able to tell it's got a box-collector on, or not....

but for the looks.... It's just plain straight forward UGGIN FUGLY.... and on a topmount no less... disgusting.... :o

there is however a hidden advantage to having the 4 runners open up into a collector.... Harmonic tuning can actually be harnessed, as there will definitely be some pulse action occurring in a system like that....

Re: collectors, lets see yours,ect
 

a guy did a chopsaw collector writeup on here:
http://forums.vwvortex.com/zerothread?id=3835589&page=1

scroll to the bottom half of the page to find it.

Re: collectors, lets see yours,ect
 

I have the same setup as that guy from VW vortex. I can't get two cuts that are the same the blade walks like crazy.

Re: collectors, lets see yours,ect
 

go really really slow, if you think your going slow enough, half it

Re: collectors, lets see yours,ect
 

well i made a collector yesterday before work, its not perfect or even close to
perfect, but i think i will use it still.
my biggest problem was wereing down the blade to fast and then it seemed to
make the next cut not the same as the first cause of blade size. i guess thats what
you get from a wilton chop saw with not much power probably never designed to
handle metal, let a long thick wall black pipe.i will say thou i have had the wilton for a
few years and it cut exhaust pipe for charge pipes and exhaust perfectly for many set-ups
over the years, also the sweet wilton has a adjuster(as many wood chop saws do) so i went
with a 15 degree cut, but after my first cut the blade was worn down quite a bit. the blades
i use are dewalt 10 inch blades, what kind of blades do you guy use?
thanks for the links and help.

Re: collectors, lets see yours,ect
 

Once done, the mani got a full extrudehone.

http://i29.tinypic.com/23j0tgi.jpg

http://i31.tinypic.com/30nbv4o.jpg

http://i30.tinypic.com/2n7pcu1.jpg

http://i31.tinypic.com/2ym6t5w.jpg

http://i25.tinypic.com/2i46q1.jpg

Re: collectors, lets see yours,ect
 

Hate to sound like a nooooob, but how do you weld the runners to the collectors where they touch like that, or in the middle?

Re: collectors, lets see yours,ect
 

Congrats on sub-par wastegate placement

Re: collectors, lets see yours,ect
 

Even better! Congrats on wasting money with extrude hone bullshit because of his poor backside weld quality.
Hey, if you can't lay a good bead buy a 36 grit flap wheel sanding disk and clean it as you go.

Im saving you time and money...

Re: collectors, lets see yours,ect
 

like it matters...

Re: collectors, lets see yours,ect
 

And extrude honing does?

Re: collectors, lets see yours,ect
 

For the middle, you cut out a little star, and weld it in. Then cut little v's for the outsides of the tube. Then slip on the colletor and run a single bead around it.

Re: collectors, lets see yours,ect
 

It sounds FAAASSSTTTT!!!

Re: collectors, lets see yours,ect
 

Lol, I hope you either have alot of money or work at a machine shop. :1

Re: collectors, lets see yours,ect
 

Hi guys here are a couple I've done. First post here. Looks like my kind of place! O0

Regular ole' 4 cylinder stuff we've sdeen a hundred times.

Bandsaw cut, 15 degree, T3 flange. 1.5" shcedule 10 stainless.

Parts cut (I see a lot of guys make equal depth cuts- I guess they then squish the collector to shape? I cut mine in proportion to the sides of the flange (rectangular flange means oblong collector).

http://www.pbase.com/capnbondo/image/95854758/large.jpg


Fit them up as pairs and tack 'em

http://www.pbase.com/capnbondo/image/95854770/large.jpg


Trim flat in the bandsaw (also so the opening is the right size for the flange- this take some planning ahead)

http://www.pbase.com/capnbondo/image/95854776/large.jpg

Fit up (note it is oval not round- this is important IMO.) Not perfect but with a little flap wheel action it will be fine.

http://www.pbase.com/capnbondo/image/95854777/large.jpg

Flange:

http://www.pbase.com/capnbondo/image/95854779/large.jpg

Weld 'er up:
http://www.pbase.com/capnbondo/image/97846987/large.jpg
http://www.pbase.com/capnbondo/image/96266667/large.jpg

Completed header:
http://www.pbase.com/capnbondo/image/96266669/large.jpg


Note odd runner layout for easy use of a pulse paired/twin scroll arrangement.


Now here is a weird one.

6 cylinder manifold and space is TIGHT:

http://www.pbase.com/capnbondo/image/90666267/large.jpg

http://www.pbase.com/capnbondo/image/89266297/large.jpg

http://www.pbase.com/capnbondo/image/89266298/large.jpg

How's THAT for nasty wastegate port placement? Eh? >:D

Not too sure how thta is going to work.... I plan on using a 60mm wastegate on it, so that will help hopefully.
Manifold currently has a T3 flange (yeah, I know...)

I am modifying to for a Twin Scroll T4 flange though and putitng a divider in! >:D

Anyways hope this was an ok first post and maybe semi-helpful. 8)

Re: collectors, lets see yours,ect
 

Both

Re: collectors, lets see yours,ect
 

Um ya. It does. :X

Re: collectors, lets see yours,ect
 

It does not to me.

Re: collectors, lets see yours,ect
 

O0

Re: collectors, lets see yours,ect
 

Ya, WE KNOW..... Wastegate placement is FAR less important than extrude honing to clean up shitty internal fitment....:X. Your position on the subject is not even worth hearing due to the statement alone. Creep.

Get it???

I made a funny boy.......

http://www.extremecroquet.org/images/foghorn.jpg

Re: collectors, lets see yours,ect
 

On the note of shitty wastegate placement... I have seen cars where even without a wastegate bolted up, the car was able to make boost on the dyno with similar placement to that gate.

Re: collectors, lets see yours,ect
 

foghorn leghorn owns!
and speaking of layout -----ups. Never have a 5+ merge collector, and especially combine that with shitty wastegate placement

lawls!

Re: collectors, lets see yours,ect
 

Agreed on the wastegate port- I'm not sure how that is going to pan out. A LOT of factors come into play with respect to wastegate function (or lack thereof LOL) so we'll see.
My 60mm wastegate should show up monday- if the flanges allow I might replace the (1.5" sched 10) pipe with a piece one size larger...moving it will be a last resort. :-X

Absolutely nothing wrong with 6 into 1 though. It's been done hundreds of times and will continue to be. If the pulses have a reasonable path and the primary entries are
relatively on-axis relative to the turbine housing, there is not reason not to- packaging/engine bay layout dictates this as much as anything.

On the other hand, when I modify it for the twin scroll T4 housing, it'll technically be two 3-into-1 housings. :D ;D


You could argue collector volume gets large but I think it is marginal in most cases.

Re: collectors, lets see yours,ect
 

Attachment 16666
Attachment 16667
Attachment 16668
Attachment 16669
Attachment 16670

Re: collectors, lets see yours,ect
 

Cool that you are cutting your own flanges. O0

Cleaning the pipe a little more before you weld it will save time in the long run- it will weld niver. Clean is everything.

In the top right of your last pic, you can see where the weld is contaminated/porous. All of that black crap on the pipe is trying to float right into your welds.

Otherwise, good on ya!

Also, checked out that link where the guy has the scary jig for doing collectors on the chop saw. I think i will pass- I have seen a 16" chopsaw disc explode, tempting those suckers is not a good idea IMO. Nice way to seperate your kneecap form the rets of your leg. ;D

Bandsaw Owns.

Re: collectors, lets see yours,ect
 

A 6 you have excessively reduced the velocity in the collector for no reason.
Where a 4-2-1 turbo manifold sucks to a 4-1, a 6-2-1, is best 6-3-1 still much better than a 6-1

Re: collectors, lets see yours,ect
 

Agreed on the velocity- that's what I was alluding to when i mentioned collector volume.

On a T3 turbine housing though i think it's really moot.

The more important question is why a ------' T3 on a 6 cylinder. :l Yea, I dunno...

Hence the re-work. I suspect it will be more like a 6-2-1, i'll end up building a pair of 3-into-1 collectors that are welded to the pulse-paired t4 manifold and try to create some sort of proper merge.

Space is horribly tight though.... inner fender sledgehammering may be in order. >:D

Re: collectors, lets see yours,ect
 

Or keep the T3 and swap a 1.06 A/R housing on it. Have it clipped if you must.
I had good results at 6250rpm on a toy v6 using a t3 .84 / t04e 60 one time.

If it's a full t3, they can make 350 on your typical 6 cylinder if you really want them too. More cylinders and displacement makes life easier than your normal i4 guys have it. Also alot less stress per cylinder part for the sme power.