anyone attempted a custom exhaust manifold?
anyone attempted a custom exhaust manifold?
![[Image: exhaust-manifold-doodle1.jpg]](http://jason.pepas.com/images/exhaust-manifold-doodle1.jpg)
11-28-2009, 11:54 PM
#3
I am thinking about building an exhaust header as well. I am wondering, how do you plan to mount it to the cylinder head? seems like you would either have to build an intake manifold on to the same flange as the exhaust, or build some sort of "step" for the bolts to tighten onto which is the same height as the one on the intake manifold. I butchered a spare exhaust manifold, and I am going to try to weld some steel header tubes onto the cast iron pieces that mount to the head, and hope it holds up.
11-29-2009, 01:09 AM
#4
(11-28-2009, 02:48 PM)cell I fooled around in solidworks for about an hour and came up with this.
Not to be nitpicky, but thats upside down.
The non-EGR log manifold is good enough for my needs. I haven't had any desire to make something else.
This post was last modified: 11-29-2009, 01:11 AM by ForcedInduction.
ForcedInduction
11-29-2009, 01:09 AM
#4
(11-28-2009, 02:48 PM)cell I fooled around in solidworks for about an hour and came up with this.
Not to be nitpicky, but thats upside down.
The non-EGR log manifold is good enough for my needs. I haven't had any desire to make something else.
11-30-2009, 04:10 PM
#5
'78 300D, OM617.912: 4spd manual, TB03 at 10PSI, 26*BTDC, DV's turned, HVAC, emissions system removed, e-fan, short ram, 3" downpipe to straight exhaust, W126 Bendix brakes, MR2 Spyder seats. 2890lbs
When my current motor gives up, my next will have a medusa looking header. haha
'78 300D, OM617.912: 4spd manual, TB03 at 10PSI, 26*BTDC, DV's turned, HVAC, emissions system removed, e-fan, short ram, 3" downpipe to straight exhaust, W126 Bendix brakes, MR2 Spyder seats. 2890lbs
11-30-2009, 04:47 PM
#6
This post was last modified: 11-30-2009, 04:47 PM by 300SD81.
Ich liebe meine Autos!
1981 Mercedes-Benz 300SD | 156K Miles | 2nd Owner | EGR Disabled [Removal Pending] | ALDA Removed | Straight Pipes | GT2256V??? | Laser Interceptor | Engine swap over summer, hopefully with GT2256V attached...
1981 Mercedes-Benz 300SD | Odo Stopped at 160K (at least 50K more) | EGR Disabled | ALDA All The Way Out | Straight pipes | FM-870 Remote Start Alarm System | B100 Biodiesel | AC Fixed x2 | Trunk crushed in
| Retired to garage.Excessive speeding? It ain't excessive till I redline!
little off topic, but does anyone know if its ok to weld a plug into the egr port? or will any welding at all cause the cast iron to crack?
Ich liebe meine Autos!
1981 Mercedes-Benz 300SD | 156K Miles | 2nd Owner | EGR Disabled [Removal Pending] | ALDA Removed | Straight Pipes | GT2256V??? | Laser Interceptor | Engine swap over summer, hopefully with GT2256V attached...
1981 Mercedes-Benz 300SD | Odo Stopped at 160K (at least 50K more) | EGR Disabled | ALDA All The Way Out | Straight pipes | FM-870 Remote Start Alarm System | B100 Biodiesel | AC Fixed x2 | Trunk crushed in
| Retired to garage.Excessive speeding? It ain't excessive till I redline!
11-30-2009, 05:02 PM
#7
1979 450SEL 6.9 - stock
1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)
2005 S55 AMG - stock
1999 SLK230 Kompressor - stock
2006 SLK55 AMG - stock
I welded mine shut with a piece of steel plate, no problems so far, about 4000 miles on the manifold since the weld.
1979 450SEL 6.9 - stock
1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)
2005 S55 AMG - stock
1999 SLK230 Kompressor - stock
2006 SLK55 AMG - stock
11-30-2009, 05:25 PM
#8
Source: http://www.lincolnelectric.com/knowledge...reheat.asp
Worst case, the manifold will have no more than 40psi on a VNT with a tight vane setting, and the T3 or K26 shouldn't hit more than 20psi, so the weld should be focused more on sealing than strength.
This post was last modified: 11-30-2009, 05:29 PM by ForcedInduction.
ForcedInduction
11-30-2009, 05:25 PM
#8
Put the manifold in the oven and get it up to about 100*f, weld it with low current and let it cool naturally.
Source: http://www.lincolnelectric.com/knowledge...reheat.asp
Worst case, the manifold will have no more than 40psi on a VNT with a tight vane setting, and the T3 or K26 shouldn't hit more than 20psi, so the weld should be focused more on sealing than strength.
11-30-2009, 05:33 PM
#9
1982 300SD: 304,xxx Super M-pump with 7.5mm elements, 265 Nozzles, GT35 water cooled turbo, M90 Supercharger, A/W Intercooler, Serpentine drive belt, 3" SS exhaust with Magnaflow muffler, 240 breather, AEM dry Filter, Manual Boost Control, EGT / Boost / EMP gauges....Moved on to other projects
1995 F-350 7.3L PSD: 230,xxx 6.0 IC, DIY Stage 1 Injectors, 17* hpop, Tony Wildman Chip, John Wood Trans, 6.4L TC, 3" down pipe, 4" straight exhaust, 310 HP on wheel dyno - 8500# dually: 0-60 in 6.98
Suzuki Samurai: VW 1.9L TD, Trackick doubler transfer case (made by me) 5.8:1 transfer case gears, YJ springs front and rear with rear missing links, wheel base extended 14", diffs welded, some day a VNT.
Rudolf_Diesel
11-30-2009, 05:33 PM #9I made a steel plug and used a tig welder and brazing rod to seal it on my old manifold.
1982 300SD: 304,xxx Super M-pump with 7.5mm elements, 265 Nozzles, GT35 water cooled turbo, M90 Supercharger, A/W Intercooler, Serpentine drive belt, 3" SS exhaust with Magnaflow muffler, 240 breather, AEM dry Filter, Manual Boost Control, EGT / Boost / EMP gauges....Moved on to other projects
1995 F-350 7.3L PSD: 230,xxx 6.0 IC, DIY Stage 1 Injectors, 17* hpop, Tony Wildman Chip, John Wood Trans, 6.4L TC, 3" down pipe, 4" straight exhaust, 310 HP on wheel dyno - 8500# dually: 0-60 in 6.98
Suzuki Samurai: VW 1.9L TD, Trackick doubler transfer case (made by me) 5.8:1 transfer case gears, YJ springs front and rear with rear missing links, wheel base extended 14", diffs welded, some day a VNT.
12-31-2009, 10:37 AM
#11
Nice Job! Someday I might build one for my engine...
1982 300SD: 304,xxx Super M-pump with 7.5mm elements, 265 Nozzles, GT35 water cooled turbo, M90 Supercharger, A/W Intercooler, Serpentine drive belt, 3" SS exhaust with Magnaflow muffler, 240 breather, AEM dry Filter, Manual Boost Control, EGT / Boost / EMP gauges....Moved on to other projects
1995 F-350 7.3L PSD: 230,xxx 6.0 IC, DIY Stage 1 Injectors, 17* hpop, Tony Wildman Chip, John Wood Trans, 6.4L TC, 3" down pipe, 4" straight exhaust, 310 HP on wheel dyno - 8500# dually: 0-60 in 6.98
Suzuki Samurai: VW 1.9L TD, Trackick doubler transfer case (made by me) 5.8:1 transfer case gears, YJ springs front and rear with rear missing links, wheel base extended 14", diffs welded, some day a VNT.
Rudolf_Diesel
12-31-2009, 10:37 AM #11^^
Nice Job! Someday I might build one for my engine...
1982 300SD: 304,xxx Super M-pump with 7.5mm elements, 265 Nozzles, GT35 water cooled turbo, M90 Supercharger, A/W Intercooler, Serpentine drive belt, 3" SS exhaust with Magnaflow muffler, 240 breather, AEM dry Filter, Manual Boost Control, EGT / Boost / EMP gauges....Moved on to other projects
1995 F-350 7.3L PSD: 230,xxx 6.0 IC, DIY Stage 1 Injectors, 17* hpop, Tony Wildman Chip, John Wood Trans, 6.4L TC, 3" down pipe, 4" straight exhaust, 310 HP on wheel dyno - 8500# dually: 0-60 in 6.98
Suzuki Samurai: VW 1.9L TD, Trackick doubler transfer case (made by me) 5.8:1 transfer case gears, YJ springs front and rear with rear missing links, wheel base extended 14", diffs welded, some day a VNT.
12-31-2009, 02:38 PM
#12
(12-31-2009, 10:22 AM)350SDL Alternative make a new one... I made this one for my OM606
Very nice! Did you make the flange + the nicely flared fittings leading up to the weld ells?
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
12-31-2009, 02:38 PM #12(12-31-2009, 10:22 AM)350SDL Alternative make a new one... I made this one for my OM606
Very nice! Did you make the flange + the nicely flared fittings leading up to the weld ells?
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
01-01-2010, 05:26 PM
#15
(01-01-2010, 03:11 PM)95e300dez I am a machinist and was wondering how long did it take to machine the flange, and what program you used. I have made the flange an a Bridgeport but am contemplating how to make the transitions.
It is programed in Mastercam.
01-02-2010, 02:10 AM
#16
'78 300D, OM617.912: 4spd manual, TB03 at 10PSI, 26*BTDC, DV's turned, HVAC, emissions system removed, e-fan, short ram, 3" downpipe to straight exhaust, W126 Bendix brakes, MR2 Spyder seats. 2890lbs
I'll be prototyping one hopefully by the end of the year at work, I just need a vgt now.haha
'78 300D, OM617.912: 4spd manual, TB03 at 10PSI, 26*BTDC, DV's turned, HVAC, emissions system removed, e-fan, short ram, 3" downpipe to straight exhaust, W126 Bendix brakes, MR2 Spyder seats. 2890lbs
01-02-2010, 03:07 PM
#17
(01-01-2010, 05:26 PM)350SDL It is programed in Mastercam.
DervTuning
01-02-2010, 03:07 PM #17Truly an amazing piece of work! Very impressive
(01-01-2010, 05:26 PM)350SDL It is programed in Mastercam.
![[Image: img1784504.jpg]](http://kuvablogi.com/nayta/thmb/img1784504.jpg)
01-03-2010, 02:30 AM
#19
(01-02-2010, 07:26 PM)jeemu(01-01-2010, 07:10 AM)350SDL I machined the flange from a solid piece of steel, and then welded bends and tube on to it.That is nice, but wg pipes should go divided on wg s valve.
Here is how i done that
It is done after the same princip on my manifold ( with a plate dividing the tube to the wastegate ) the manifold was just not finished when i took the pictures.
(01-02-2010, 07:26 PM)jeemu(01-01-2010, 07:10 AM)350SDL I machined the flange from a solid piece of steel, and then welded bends and tube on to it.That is nice, but wg pipes should go divided on wg s valve.
Here is how i done that
01-06-2010, 11:44 AM
#20
(01-01-2010, 07:10 AM)350SDL I machined the flange from a solid piece of steel, and then welded bends and tube on to it.
How much would you charge for that assembly?!?!?! AMAZING work!!
John Robbins
'05 E320 CDI - 118k - Faaaaaast!!
'87 300TD - 317k - Cracked head... but an OM606 is on the way!
'79 300SD - 295k - Bad engine = project car!
(01-01-2010, 07:10 AM)350SDL I machined the flange from a solid piece of steel, and then welded bends and tube on to it.
How much would you charge for that assembly?!?!?! AMAZING work!!
John Robbins
'05 E320 CDI - 118k - Faaaaaast!!
'87 300TD - 317k - Cracked head... but an OM606 is on the way!
'79 300SD - 295k - Bad engine = project car!
01-06-2010, 01:58 PM
#21
(01-01-2010, 05:26 PM)350SDL It is programed in Mastercam.
That piece is a thing of beauty. VERY nice work.
Are you handing out copies of that Mastercam CAD/CAM file?
Cheers,
Matt
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
01-06-2010, 01:58 PM #21(01-01-2010, 05:26 PM)350SDL It is programed in Mastercam.
That piece is a thing of beauty. VERY nice work.
Are you handing out copies of that Mastercam CAD/CAM file?
Cheers,
Matt
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
01-06-2010, 04:10 PM
#22
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.
2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
Handing out copies? Shoot, I'd PAY for a copy!
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.
2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
01-06-2010, 05:10 PM
#23
(01-06-2010, 04:10 PM)E300TSC Handing out copies? Shoot, I'd PAY for a copy!
Good catch - I should have been more specific. I'd gladly pay for a copy as well.
Cheers,
Matt
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
01-06-2010, 05:10 PM #23(01-06-2010, 04:10 PM)E300TSC Handing out copies? Shoot, I'd PAY for a copy!
Good catch - I should have been more specific. I'd gladly pay for a copy as well.
Cheers,
Matt
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
01-06-2010, 05:28 PM
#24
welding bends 37mm. inside dia.
Sorry I an not giving away the CAD or CAM file. ( it took quite some time to make... )
Anyway i dount think you can use the CAM file anyway as it all programed in milimeters.( with metrich tools ).
I think all US Mashineshops / Mastercam users use inch.
I can sell the flange for 300USD. the flange is made in mild steel and is made for standard
welding bends 37mm. inside dia.
Sorry I an not giving away the CAD or CAM file. ( it took quite some time to make... )
Anyway i dount think you can use the CAM file anyway as it all programed in milimeters.( with metrich tools ).
I think all US Mashineshops / Mastercam users use inch.
01-06-2010, 06:13 PM
#25
(01-03-2010, 02:30 AM)350SDL It is done after the same princip on my manifold ( with a plate dividing the tube to the wastegate ) the manifold was just not finished when i took the pictures.Do you got a picture when its finished?
(01-02-2010, 07:26 PM)jeemu(01-01-2010, 07:10 AM)350SDL I machined the flange from a solid piece of steel, and then welded bends and tube on to it.That is nice, but wg pipes should go divided on wg s valve.
Here is how i done that
(01-03-2010, 02:30 AM)350SDL It is done after the same princip on my manifold ( with a plate dividing the tube to the wastegate ) the manifold was just not finished when i took the pictures.Do you got a picture when its finished?
(01-02-2010, 07:26 PM)jeemu(01-01-2010, 07:10 AM)350SDL I machined the flange from a solid piece of steel, and then welded bends and tube on to it.That is nice, but wg pipes should go divided on wg s valve.
Here is how i done that
01-07-2010, 01:07 PM
#27
(01-06-2010, 05:28 PM)350SDL Sorry I an not giving away the CAD or CAM file. ( it took quite some time to make... )
Sorry - I was joking about wanting the file. You hold tight to that and with good reason.
Cheers,
Matt
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
01-07-2010, 01:07 PM #27(01-06-2010, 05:28 PM)350SDL Sorry I an not giving away the CAD or CAM file. ( it took quite some time to make... )
Sorry - I was joking about wanting the file. You hold tight to that and with good reason.
Cheers,
Matt
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
10-18-2010, 10:50 PM
#28
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
10-18-2010, 10:50 PM #28any new work on this?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
10-18-2010, 11:24 PM
#29
(01-06-2010, 05:28 PM)350SDL I think all US Mashineshops / Mastercam users use inch.
I must be the odd duck that doesn't, I'm running a Hardinge 3 axis turning center in metric right now with imperial tooling, it's just a G21/G20 to switch between.
I prefer metric, much much easier to work with when everything you're doing is already metric, not to mention there's no bloody freaking fractions, M12 fits in a (clearanced) 12mm hole, etc.
Mastercam can also convert on the fly to/from metric, but I find mastercam on a turning center to be daunting... I can punch out a longhand program quicker than it takes to set all the parameters, select the right post, etc. That being said, irregular contours, weird necking, and complex surface live tooling operations are a breeze with Mastercam and Autodesk Inventor.
Don't ever give up your finished files/programs, just give out pictures and sell products, it helps keep the market fresh.
1990 Power Ram 50 V6 SOHC 24V 6g72
I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
(01-06-2010, 05:28 PM)350SDL I think all US Mashineshops / Mastercam users use inch.
I must be the odd duck that doesn't, I'm running a Hardinge 3 axis turning center in metric right now with imperial tooling, it's just a G21/G20 to switch between.
I prefer metric, much much easier to work with when everything you're doing is already metric, not to mention there's no bloody freaking fractions, M12 fits in a (clearanced) 12mm hole, etc.
Mastercam can also convert on the fly to/from metric, but I find mastercam on a turning center to be daunting... I can punch out a longhand program quicker than it takes to set all the parameters, select the right post, etc. That being said, irregular contours, weird necking, and complex surface live tooling operations are a breeze with Mastercam and Autodesk Inventor.
Don't ever give up your finished files/programs, just give out pictures and sell products, it helps keep the market fresh.
1990 Power Ram 50 V6 SOHC 24V 6g72
I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
10-19-2010, 08:31 AM
#30
(10-18-2010, 11:24 PM)300D50 Don't ever give up your finished files/programs, just give out pictures and sell products, it helps keep the market fresh.
I agree - which is why I jokingly asked for the CAD file earlier.
In related news, hope to test out BobCAD/CAM integrated with SolidWorks pretty soon.
/hijack
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
10-19-2010, 08:31 AM #30(10-18-2010, 11:24 PM)300D50 Don't ever give up your finished files/programs, just give out pictures and sell products, it helps keep the market fresh.
I agree - which is why I jokingly asked for the CAD file earlier.
In related news, hope to test out BobCAD/CAM integrated with SolidWorks pretty soon.
/hijack
'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
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