Project adopt-a-header
 

So a guy I know had someone building him a header and they didn't end up having time/energy to finish it. So I agreed to help him out.

This is another volvo 8V manifold- the ones I build are bottom mount, but I was interested in making a jig so I could also make top mount manifolds.

So anyways half the welding/fitup isn't mine, but the interesting part was that it was designed to be used with an internal watsegate.

I was like "wtf, internal on a twinscroll setup for 400-500hp? Uh no. I'm putting a ------- external pipe on it."

Clearance for it was trciky so here's what I came up with:

Attachment 13209

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The manifold itself:

Attachment 13213

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The whole thing's not really my style, but it was kinda fun to try to take over a project.

I'll make a jig and simplifiy the design a lot.

Re: Project adopt-a-header
 

Nice work. I wouldn't even want to try to weld that clusterfuck up :y

Re: Project adopt-a-header
 

LoL He obviously gave up after he realized he put more thought into using lots of materials to make something "cool" looking than he did how he was going to deal with all the restricted welds LoL!

Have fun with that LoL!

Re: Project adopt-a-header
 

Yeah exactly, it's at least 23.5 times more complicated than it needs to be. :S :1

I've got it all welded up now, but yeah some of it left me scratching my head. Who welds up runners solid before even completing the whole design? What is you need to tweak something? lol.

Re: Project adopt-a-header
 

werd

Re: Project adopt-a-header
 

Looks sick. But your welding it to cold. What car is that for?

Re: Project adopt-a-header
 

boy, that doesn't look like fun at all. congrats on getting it all welded up.

Re: Project adopt-a-header
 

Thanks guys- yeah I was cursing the guy who started it. Lots of tungsten grinding going on for a couple of them.


Bitches suck,

you think the welds on the wastegate pipe are too cold? The welds shown on the runners aren't mine...
If you mean the welds on the watsgeate part, what about them suggests that to you?

Re: Project adopt-a-header
 

Everything but the weave in the collector could stand to be hotter with the right amount of filler added. Doesn't matter, you didn't weld any of it.

Re: Project adopt-a-header
 

if you start mass producing those, i'm going to buy stock in ace stainless


thats one hell of a mess, but props on finishing it. got any pictues of it installed?

Re: Project adopt-a-header
 

Nah the guy who owns it doesn't live near me and hasn't picked it up yet. I'll have him take some pics after he installs it.

And I hear you guys on the welds, I could tell form some of the unfinished welds he was running a root pass with (it looked like) no filler that looked ok, but and then capping it- the caps are pretty cold. Mine are maybe a touch cold on the wastegate bit, too, but I wasn't too worried about it in this case.

I actually probably will make "copies" - but I will re-work the runners first, I'd have to charge way more than they'd be worth piecing them together like friggin jigsaw puzzles. LOL.

Re: Project adopt-a-header
 

wow that gave me a head ache trying to figure out all teh routing on that damn thing..none the less i would still rock it

Re: Project adopt-a-header
 

But the question is do you have the $700-800 ready to go so he can make a second. :D

Re: Project adopt-a-header
 

Werd. To that end I just had a shop order 4 of these - d'oh. Sure hope I can simplify the runners or I'll lose my ass. :P

Re: Project adopt-a-header
 

What size filler rod are you using?

Re: Project adopt-a-header
 

I don't know what the other dude used on the manifold- the only welds that are mine are the gold ones on the wastegate pipe itself.

I use 1/16th for pipe-to-pipe welds, and 3/32 for pipe to flange welds. I also use 309L instead of 308 or 308L. It over matches on chromium content and nickel content even more than 308, which I think is a good thing, and it is barely more expensive. I don't think many other people do and it's not not necessary though. I am up around 70-80 amps, moving fairly fast (it's more smooth than fast I guess, still not quite as far as when you're in the groove with a MIG) and dipping steady- almost 2 little dips per second- more than 1 dip per second anyways.

You can see some of it (including mine- this mani is sched 40 and I wasn't really used to it) was a little cold- this keeps the puddle from really wetting out, and the slower speed needed results in "blobs" of filler dripping off into the weld which makes the problem even worse. A lot of folks struggle with having "blobs" of filler drip off the end of the rod. I improved a lot when I discovered the fix is counter intuitive- more heat, not less.

Re: Project adopt-a-header
 

Yeah. I'm having a problem like that with a manifold that I'm welding, but it's magnified by someone's suggestion that i should weld with 3/32 filler rod and the fact that I'm using 316l on 304. Oh well. When i get around to it I'll buy some of the proper rod. Just trying to see what other people on here who actually weld manifolds are using. Thanks for the info.

Re: Project adopt-a-header
 

3/32 should still be ok. Lots of fast dips and more heat. Big bevel. 1/16 or 3/32 is personal preference on sched 10. 316 is not a great filler for 304 though. You can use it but it's not ideal and more money for no real benefit.

Re: Project adopt-a-header
 

I got like 15lbs of 316 3/32 filler for 25 bucks although I'm not really good enough to use it yet.

Re: Project adopt-a-header
 

Phenominal buy! Normally more than $10 a pound!
Make small fast dipping motions, dont try to stream the metal off the rod. That'll work for afew MM then you'll get yourself in trouble real fast.
Using 316 on 304, that 316 flows into the 304 literally like astroglide. Real wet & flows fast.


How thick is the pipe rawr sch-10?

Re: Project adopt-a-header
 

I can't weld for ----. My TIGing looks like most peoples flux core. I'm going to sell my ---- once i finish my manifold/downpipe.

Re: Project adopt-a-header
 

i know the feeling...