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+--- Thread: anyone attempted a custom exhaust manifold? (/showthread.php?tid=885)
anyone attempted a custom exhaust manifold? - cell - 11-28-2009
has anyone attempted to make a custom exhaust manifold from weldable elbows?
I fooled around in solidworks for about an hour and came up with this. not sure if I'll go anywhere with it, but I thought I'd throw the idea out there.
![[Image: exhaust-manifold-doodle1.jpg]](http://jason.pepas.com/images/exhaust-manifold-doodle1.jpg)
RE: anyone attempted a custom exhaust manifold? - lars - 11-28-2009
Nice tool. What is your tuning goal? tuned up stock pump? You should have pretty high soup- and airflow for that custom manifold to be necessary.
RE: anyone attempted a custom exhaust manifold? - shredator - 11-28-2009
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.
RE: anyone attempted a custom exhaust manifold? - ForcedInduction - 11-29-2009
(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.
RE: anyone attempted a custom exhaust manifold? - kamel - 11-30-2009
When my current motor gives up, my next will have a medusa looking header. haha
RE: anyone attempted a custom exhaust manifold? - 300SD81 - 11-30-2009
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?
RE: anyone attempted a custom exhaust manifold? - MB TECH - 11-30-2009
I welded mine shut with a piece of steel plate, no problems so far, about 4000 miles on the manifold since the weld.
RE: anyone attempted a custom exhaust manifold? - ForcedInduction - 11-30-2009
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/articles/content/castironpreheat.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.
RE: anyone attempted a custom exhaust manifold? - Rudolf_Diesel - 11-30-2009
I made a steel plug and used a tig welder and brazing rod to seal it on my old manifold.
RE: anyone attempted a custom exhaust manifold? - 350SDL - 12-31-2009
Alternative make a new one... I made this one for my OM606
RE: anyone attempted a custom exhaust manifold? - Rudolf_Diesel - 12-31-2009
^^
Nice Job! Someday I might build one for my engine...
RE: anyone attempted a custom exhaust manifold? - HoleshotHolset - 12-31-2009
(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?
RE: anyone attempted a custom exhaust manifold? - 350SDL - 01-01-2010
RE: anyone attempted a custom exhaust manifold? - 95e300dez - 01-01-2010
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.
RE: anyone attempted a custom exhaust manifold? - 350SDL - 01-01-2010
(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.
RE: anyone attempted a custom exhaust manifold? - kamel - 01-02-2010
I'll be prototyping one hopefully by the end of the year at work, I just need a vgt now.haha
RE: anyone attempted a custom exhaust manifold? - DervTuning - 01-02-2010
Truly an amazing piece of work! Very impressive
(01-01-2010, 05:26 PM)350SDL It is programed in Mastercam.
RE: anyone attempted a custom exhaust manifold? - jeemu - 01-02-2010
(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
![[Image: img1784504.jpg]](http://kuvablogi.com/nayta/thmb/img1784504.jpg)
RE: anyone attempted a custom exhaust manifold? - 350SDL - 01-03-2010
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
RE: anyone attempted a custom exhaust manifold? - Tymbrymi - 01-06-2010
(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!!
RE: anyone attempted a custom exhaust manifold? - HoleshotHolset - 01-06-2010
(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
RE: anyone attempted a custom exhaust manifold? - E300TSC - 01-06-2010
Handing out copies? Shoot, I'd PAY for a copy!
RE: anyone attempted a custom exhaust manifold? - HoleshotHolset - 01-06-2010
(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
RE: anyone attempted a custom exhaust manifold? - 350SDL - 01-06-2010
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.
RE: anyone attempted a custom exhaust manifold? - jeemu - 01-06-2010
(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
RE: anyone attempted a custom exhaust manifold? - 350SDL - 01-07-2010
Sorry i dident take a picture of the finished manifold..
But anyway it is 95% finished on the picture, only a little longer tube on the exh. for the wastegate
and a plate in the center to divide the 2 chambers.
RE: anyone attempted a custom exhaust manifold? - HoleshotHolset - 01-07-2010
(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
RE: anyone attempted a custom exhaust manifold? - willbhere4u - 10-18-2010
any new work on this?
RE: anyone attempted a custom exhaust manifold? - 300D50 - 10-18-2010
(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.
RE: anyone attempted a custom exhaust manifold? - HoleshotHolset - 10-19-2010
(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