My turbo out of engine bay getting a face lift

[Schmieder]

The blue tape is a temp hold for tack welding. Built compact and sturdy yet high flowing. All the vacuum/boost hoses are well secured like power lines. They aren't moving and therefore will never touch anything too hot and melt the hose.

the manifold has a 30 degree turn into the wastegate channel for smooth transitions. the dump side of the wastegate has a slight venturi effect (vacuum) when it opens it will get a quick pull from the vacuum. It also should help mix the two exhaust streams. The DP and WG dump pipe were calculated the perfect diameter for equal speed flow at 8psi between 3400-5500 RPM. So neither exhaust flow will impact the other substantially. They will merge better if they both flow at the same speed. A seperate (not shown yet) chamber with the perfect diameter for both exhaust flow will be attached and gently taper back to 2.5" exhaust.

The turbo manifold (cross-over) is highly polished from tip to tip, even in the wastegate pocket and valve was polished well. Better heat reflection and less carbon build up over time.

[2.8-350TBI]

What are you welding with?

Looks like it needs shielding gas

[Schmieder]

What are you welding with?

Looks like it needs shielding gas

Sort of. I am using a Flux Core welder, a Lincoln and it throws a nice hot weld but the area you are looking at (I know, the area between the merge) was a different spool of flux wire. Same type but different brand and the shielding on the wire sucks big time. The first bead was great and it was tested with zero leaks at 20 psi. But I still tossed 2 more layers/beads to ensure it holds from the stresses.

Though, I don't mind the splatter because it really helps grab the exhaust wrap when cutting for merges, O2 sensors, etc. I use damp towels to shield delicate areas like the inside, bolt holes, flange faces, etc. After knocking off the slag it's not too bad.

But don't get me wrong, I'de LOVE a TIG welder. That and I want to weld aluminum too. I know I can design and build a kick a$$ intake manifold.

Aside from the semi-sloppy welds I am proud of the path I built for the airflow. Every inch is polished just right (soft for intake, mirror for exhaust) and all bends are smooth internally. Especially the Downpipe.