home made 40r kit mock up. - Page 3

***Neanderthal Racing*** · 11-09-2006, 07:34 PM

dude, youre going to look like a freakin' genius if that all works out. i really admire your fabrication skills. the turbo location is killer. it's reminiscent of that crazy russian sti on that dyno video.

STi_1212 · 11-09-2006, 07:45 PM

Lookin good! How long has this taken you?

fobiawrx · 11-09-2006, 08:10 PM

on and off like 4 weeks

**lackskill** · 11-09-2006, 08:47 PM

that TB looks like it is made of some pretty thin material, i dont think it will hold boost and if it does I would imagine you will get pressure drop and cracking due to expansion/contraction from on/off boost. It is very difficult to get 2" sch 80 (~5/16" wall thickness) seamless pipe to hold more than 50 psi without finding leaks in welds, I think 20psi on that would be impossible. I dont want to rain on your parade, I just would hate to see you waste your time. Welds are your enemy on a pressurized cavity, hence most high pressure intakes being cast, thick and heavy.

STi_1212 · 11-09-2006, 08:49 PM

I'm also interested to know did you make it free hand or designed it (drafting by hand, auto-cad, or some type of 3-d cad software ie. Solidworks / Inventor)?
Sorry for all the questions

fobiawrx · 11-09-2006, 08:55 PM

been serching around and looking at all the cars that have been making alot of power and this is what i cam up with. more free hand then maped out but with close mesurments. now from what i read a bigger plentum means more top end hp and longer runners with a smaller plenum means more tq. hear is my happy medum. 2.25 16 gage runners and 3/16 sheet metal. should hold up fine.

nero9 · 11-10-2006, 12:11 PM

nice work, want a job?

When I'm making the Indycar oil coolers I have to pressure test them at 50psi. I make the end tanks from 16ga 5052 aluminum. The tanks are hand formed and have compound radii, which makes them very strong and light. So definitely make some plugs and pressure test your bits by filling with shop air to at least what your boost pressure will be. Then either submerge in water looking for bubbles, or use a soap/water solution sprayed to the outside and look for bubbles. This should be done as the last step before paint or polish. If it holds, your done. If not, fix the leaks. I have had success with sheet metal intakes by bracing the plenum for expansion/contraction. I use 1/2" or 3/4" round stock. Drill a hole through the plenum on both sides, insert rod, weld in place. This keeps the movement to a minimum so the welds don't crack.

Good luck.

fobiawrx · 11-10-2006, 12:27 PM

Quote:

Originally Posted by nero9

nice work, want a job?

When I'm making the Indycar oil coolers I have to pressure test them at 50psi. I make the end tanks from 16ga 5052 aluminum. The tanks are hand formed and have compound radii, which makes them very strong and light. So definitely make some plugs and pressure test your bits by filling with shop air to at least what your boost pressure will be. Then either submerge in water looking for bubbles, or use a soap/water solution sprayed to the outside and look for bubbles. This should be done as the last step before paint or polish. If it holds, your done. If not, fix the leaks. I have had success with sheet metal intakes by bracing the plenum for expansion/contraction. I use 1/2" or 3/4" round stock. Drill a hole through the plenum on both sides, insert rod, weld in place. This keeps the movement to a minimum so the welds don't crack.

Good luck.

got any pics of the plentum bracing

Pitcherman · 11-10-2006, 12:53 PM

Looks nice. Hope you don't melt your front tire with that 6" down pipe

bullittman68 · 11-10-2006, 01:14 PM

dang I can't wait to see the video when all of this comes together and you open up the cutout!!! dang that turbo is gonna sound sick!!

munky69 · 11-10-2006, 03:28 PM

you are awesome! such an original idea!! great work, keep it up! when it's done i think pretty much any tuner shop in the world would hire you

fobiawrx · 11-10-2006, 09:50 PM

wow thanks for all the support! nice to know you all like what i am doing

STi_1212 · 11-11-2006, 11:26 AM

How long approximately till you get it up and running?

XxSCAxX · 11-11-2006, 11:49 AM

pretty badass. cant wait to see it all together and running.

fobiawrx · 11-11-2006, 02:24 PM

Quote:

Originally Posted by STi_1212

How long approximately till you get it up and running?

hopefully spring. once i get the parts built and finished then i will buy the parts for it. kind of depends on how much money i make over the winter. and tax time of corce.

11-09-2006, 07:34 PM	#31
*Neanderthal Racing* GT R US Car: CUTN EDG project Fav Mod: $20. mudflaps from auto zone Location: my cave Posts: 5,893 IWSTI Addict since: Dec 2003 Trader Rating: (1)	dude, youre going to look like a freakin' genius if that all works out. i really admire your fabrication skills. the turbo location is killer. it's reminiscent of that crazy russian sti on that dyno video. This ad is not endorsed by this member. Please register or login to hide this ad.

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11-09-2006, 07:45 PM	#32
STi_1212 Grassroots STI Racer Location: Toronto, Ontario Posts: 554 IWSTI Addict since: Jun 2006 Trader Rating: (0)	Lookin good! How long has this taken you?

11-09-2006, 08:10 PM	#33
fobiawrx STI Driver Car: white 04 sti Fav Mod: s374 Location: mpls! Posts: 216 IWSTI Addict since: Dec 2005 Trader Rating: (0)	on and off like 4 weeks

11-09-2006, 08:47 PM	#34
lackskill Moderator Car: 05 Ram 3500 CTD Fav Mod: Majin Posts: 14,776 IWSTI Addict since: Apr 2006 Trader Rating: (9)	that TB looks like it is made of some pretty thin material, i dont think it will hold boost and if it does I would imagine you will get pressure drop and cracking due to expansion/contraction from on/off boost. It is very difficult to get 2" sch 80 (~5/16" wall thickness) seamless pipe to hold more than 50 psi without finding leaks in welds, I think 20psi on that would be impossible. I dont want to rain on your parade, I just would hate to see you waste your time. Welds are your enemy on a pressurized cavity, hence most high pressure intakes being cast, thick and heavy.

11-09-2006, 08:49 PM	#35
STi_1212 Grassroots STI Racer Location: Toronto, Ontario Posts: 554 IWSTI Addict since: Jun 2006 Trader Rating: (0)	I'm also interested to know did you make it free hand or designed it (drafting by hand, auto-cad, or some type of 3-d cad software ie. Solidworks / Inventor)? Sorry for all the questions

11-09-2006, 08:55 PM	#36
fobiawrx STI Driver Car: white 04 sti Fav Mod: s374 Location: mpls! Posts: 216 IWSTI Addict since: Dec 2005 Trader Rating: (0)	been serching around and looking at all the cars that have been making alot of power and this is what i cam up with. more free hand then maped out but with close mesurments. now from what i read a bigger plentum means more top end hp and longer runners with a smaller plenum means more tq. hear is my happy medum. 2.25 16 gage runners and 3/16 sheet metal. should hold up fine.

11-10-2006, 12:11 PM	#37
nero9 Junior STI Driver Car: PSM '04 STi Fav Mod: 6pt harness Location: Mooresville, NC Posts: 134 IWSTI Addict since: Apr 2004 Trader Rating: (0)	nice work, want a job? When I'm making the Indycar oil coolers I have to pressure test them at 50psi. I make the end tanks from 16ga 5052 aluminum. The tanks are hand formed and have compound radii, which makes them very strong and light. So definitely make some plugs and pressure test your bits by filling with shop air to at least what your boost pressure will be. Then either submerge in water looking for bubbles, or use a soap/water solution sprayed to the outside and look for bubbles. This should be done as the last step before paint or polish. If it holds, your done. If not, fix the leaks. I have had success with sheet metal intakes by bracing the plenum for expansion/contraction. I use 1/2" or 3/4" round stock. Drill a hole through the plenum on both sides, insert rod, weld in place. This keeps the movement to a minimum so the welds don't crack. Good luck.

11-10-2006, 12:53 PM	#39
Pitcherman STI Master Car: 04 JVP STi Fav Mod: Blitz NUR Spec R Location: B.F.E, Texas Posts: 7,979 IWSTI Addict since: Apr 2004 Trader Rating: (3)	Looks nice. Hope you don't melt your front tire with that 6" down pipe

11-10-2006, 01:14 PM	#40
bullittman68 Amateur STI Driver Posts: 44 IWSTI Addict since: Oct 2006 Trader Rating: (0)	dang I can't wait to see the video when all of this comes together and you open up the cutout!!! dang that turbo is gonna sound sick!!

11-10-2006, 03:28 PM	#41
munky69 S204 Racer Car: 04 STi, 06 Altima Fav Mod: jailbreak Location: SOsocal Posts: 3,066 IWSTI Addict since: Aug 2003 Trader Rating: (2)	you are awesome! such an original idea!! great work, keep it up! when it's done i think pretty much any tuner shop in the world would hire you

11-10-2006, 09:50 PM	#42
fobiawrx STI Driver Car: white 04 sti Fav Mod: s374 Location: mpls! Posts: 216 IWSTI Addict since: Dec 2005 Trader Rating: (0)	wow thanks for all the support! nice to know you all like what i am doing

11-11-2006, 11:26 AM	#43
STi_1212 Grassroots STI Racer Location: Toronto, Ontario Posts: 554 IWSTI Addict since: Jun 2006 Trader Rating: (0)	How long approximately till you get it up and running?

11-11-2006, 11:49 AM	#44
XxSCAxX Spec C Club Car: 05 AW 30r STi Fav Mod: Perrin 30r Kit Location: Campbell Hall, NY Posts: 1,552 IWSTI Addict since: Apr 2005 Trader Rating: (5)	pretty badass. cant wait to see it all together and running.