Turbo Manifolds

[davepug205 7]

i didn't mean paid by a forum member i meant work.

 

i don't think that i would be happy 'selling' a turbo manifold till im happy that it works well!

 

i am looking to move forward quite quickly, as soon as we have perfected the design and got one easly made ill give you a shout!

 

 

thanks james

 

 

Thats great James, when your happy with a 16v one the moneys on its way to you

[Sicknote 0]

the dp manifold is a very good design in the fact that we managed to squeeze a t4 roller bearing turbo into our 16v conversion with a full 3" downpipe and exhaust system , the positioning of the manifold is pretty much perfect allowing water pipes , oil pipes , boost pipes etc etc all fitted into a 205 engine bay is very hard going.

 

 

If you look at the DP mani i.e the love collector 2 the only way it can get equal length runners is to turn it into a top mount turbo and use very tight radius bends which isn't ideal for flow and still gives packaging issues with the MC.

 

With regard to the above posts, do the DP-Engineering manifolds fit a RHD 205, or not?

 

Great idea, James!

Edited May 28, 2009 by Sicknote

[tom_m 0]

With regard to the above posts, do the DP-Engineering manifolds fit a RHD 205, or not?

 

Great idea, James!

 

16v Yes

 

8v Not really

[whizzer71 0]

Thats great James, when your happy with a 16v one the moneys on its way to you

 

Ill 2nd that cant wait to get my hands on one !

 

[Sicknote 0]

8v Not really

 

Thanks for the reply, Tom;

 

Do you have a cunning plan to get your DP manifold to fit your XU10 J2T, then?

 

Cheers

[tom_m 0]

Thanks for the reply, Tom;

 

Do you have a cunning plan to get your DP manifold to fit your XU10 J2T, then?

 

Cheers

 

about three years of work (on and off) and a big shoe horn!

[Sicknote 0]

Look forward to reading about it!

[wracing 19]

just a quick update, progress is slow as i dont get payied till the end of the month not long though and then i can get one of these bad boys made!

 

james

[All Praise The GTI 3]

well you know i want one mate

[Malachy 0]

very interested in a kit form of one of these.16v that is

Regards

Andy

[16v205 9]

I'll have a 8v in kit form please when your making them, i should be able to weld them up ok.

 

Rich

[kent 0]

Great work!

[James_R 3]

I'd be after an s16 item with a T25 flange and downpipe when you get it worked out

 

any word back from DP?

[ALEX 98 1 Cars]

Good use of Solidworks there.

 

 

I use Solidworks myself at work, but never can be ar*ed to do anything like this as I'd had enough of it by 5 O'clock.

I'm in the business of mechanical design and am just old enough to have experience from both ends from using a Drawing board to AutoCAD to Solidworks. You'd never take a step back, I find using AutoCAD is laborious now in the same comparison it was moving from the Drawing board.

 

Admittedly computers are making life easier in many aspects, so those without experience or lack of interest in them fall behind and are usually naive towards them.

1st hand experience is still good, but I don't think is valued as much as it was before you could create a fully simulated prototype, that can be calculated by a growing list of flow, stress & pressure tests from a few clicks of a mouse button.

 

I showed a senior designer once who was close to retirement on what this package could actually do.

His jaw just dropped and said in 10 mins I'd done a full week of his work, I'm not kidding, he pulled out a folder from a previous similar job that what 3" thick with calculations!

 

TBH though I'd be lost without a computer and I'm sure many out there would be too, for that I have great respect for the generation outside the modern computer age, as I can see they didn't have it as easy as us when they were our age.

[DrSarty 90 1 Cars]

Fascinating thread.

 

Not quite sure why there's been bits of 'tension' here and there.

 

The science behind design and manufacturing in general amazes me, but all that goes and has gone on for years behind the internal combustion engine will remain a passion of mine and I hope my son picks it up too.

 

Good work by James on this IMO. I was thinking that £900 is a lot of money for a manifold, but I've seen some projects on here with £3,000 complete systems so I suppose it's in keeping. But what do I know eh?

[jonnyturbo 3]

whats happenin with this then?

[Cameron 16]

That level of welding to me at least, doesn't look like it is particulalry suited to DIY, so even though the manifold may be cheap in component form it is going to cost a fair whack for someone to weld it up for you to a good standard. Also the standard of the welding is what defines how reliable it is to cracks etc...and also how well it flows internally...

 

I can tell you, it isn't!

I worked at BTB for just over a year and I had had a fair bit of welding experience before I started. It takes a huge amount of practise to be able to weld something as complex as a manifold! When I started I needed constant step-by-step tutorial on my first lot of manifolds. Its not just about being able to get the torch in the right place, but you need to know what to weld in what order, where to start the weld and where to finish in order to get the strength and an gas-tight seal. Can anybody honestly tell me what order you would weld that first design in, and how you would get the collector to seal?

 

I'm not trying to put you off, but I think you're letting yourself into a world of trouble allowing novices to weld up their own manifolds! You'll be the one who's name gets dragged through the mud when your manifolds "don't fit properly" or leak. You're better off just supplying the things welded up.

 

Now, a couple of hints..

Don't go overboard with your material specs, you don't need 3mm steel for the collector, it's just going to make the fabrication difficult and more time consuming. The thickest material we've ever used on a turbo mani was 2mm, and that was for a 700+bhp biturbo V8 where the turbo flange was little over 4" from the head flange! You can easily get away with 1.6mm. An example for you, Radical SR3 & 8 manifolds are 1.6mm mild steel.

 

You'll need to bolt the flange down to something when you weld it too, otherwise it will warp like a bastard no matter how thick it is. 8mm C-section steel beam is the best thing to use.

Edited August 1, 2009 by Cameron

[Daviewonder 533 3 Cars]

any news on this?

[ALEX 98 1 Cars]

Just throwing ideas about but is it possible to make a Turbo manifold from a CNC milled block?

I know nothing about turbos BTW

[Swazy 0 1 Cars]

just a quick update, progress is slow as i dont get payied till the end of the month not long though and then i can get one of these bad boys made!

 

james

 

Could it be that your inbox is full?

[magic 1 1 Cars]

i builted one up for my 205 cti T16

765mm equal lenghts ..

 

 

 

 

 

 

 

 

 

 

 

took me nearly one week

hole story here

http://forum.205gtidrivers.com/index.php?s...05164&st=20

Edited August 11, 2009 by magic

[shalmaneser 26]

Just throwing ideas about but is it possible to make a Turbo manifold from a CNC milled block?

I know nothing about turbos BTW

 

Anything is possible! Thought whether you'd want to is another question, cost would be ridiculous, it would have to be made in several parts and bolted together, probably be heavier than a welded item...the list goes on!

 

I mean, you could CNC a paperclip, but what would the point be?

[DrSarty 90 1 Cars]

I mean, you could CNC a paperclip, but what would the point be?

 

Don't suggest that. Each paperclip is handcrafted, being cut from a really long rod and bent by hand around the original mandrel produced in 1829, and packed with care. Yes: even the ones from WH Smith.

 

[NickMi 0]

Any news on these manifolds?

I have a guy who tig welds manifolds for a living so i would be happy to have one off you and get it welded up and test it on a vehicle, I also have free use of a rolling road for testing.

Cheers

[Cameron 16]

 

Mmm, welding round those collectors must have been fun with all the primaries in place!

 

Nice job though, tubing looks horrendously thick! What is it, 2mm?