Welding on turbo housing for the first time

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I need to weld a 90 elbow onto a turbo housing to re direct the IC piping. I will be using a dynasty 200 dx and 3/32 red. This is my first time welding on cast aluminum so any tips on settings or techniques would greatly be appreciated.
Reply:Are you welding the flange directly to the turbo housing?  Why not use a v band flange?
Reply:This is what I need to do Attached Images
Reply:Just keep it clean, put a slight bevel on both sides, and make sure that with any melt or burnthrough, that there is nothing there that can be dislodged.  In all honesty, I would sooner put a v band flange on the turbo and elbow, rather than welding the two directly together, especially if it's an expensive turbo.  Gives you many more options, and won't hurt resale.
Reply:Somewhere I've got a picture of almost eexactly the same thing.  It was a turbo for on a BMW, and to get it to fit the housing is cut WAY back and I welding a cast elbow on.  I think I had to cut into the area where the tag is on the picture posted above to get it tight enough to fit.No real pointers other than the usual clean and clean it again.  A litt preheat won't hurt since it's going to heatsink a lot at first.
Reply:Originally Posted by SupeJust keep it clean, put a slight bevel on both sides, and make sure that with any melt or burnthrough, that there is nothing there that can be dislodged.  In all honesty, I would sooner put a v band flange on the turbo and elbow, rather than welding the two directly together, especially if it's an expensive turbo.  Gives you many more options, and won't hurt resale.
Reply:I've done quite a few turbo  and supercharger systems and I wouldn't have done it that way. I would have let the compressor stock- that way you can do an easy exchange if the cold-side wheel explodes and damages the housing. It also makes for an easier direct bolt-on upgrade in the future.Remember....if you're not putting at least two atmospheres into the manifold (28PSI), it isn't worth turbocharging it! Once you crack an cast aluminum intake manifold, you have enough boost! (guilty...110 PSI on a IVECO Diesel tractor pulling engine. It had two Garrett sequential turbos with water cooled centers. The interecooler was between the two compresor stages. The first stage did about 40 PSI and the second one made the real boost). You should have seen the 60' plume of smoke and heard the sound under load. It would make the hair on you balls tingle.
Reply:Here is a pic of the one I mentioned above:On this instance the end of the outlet on the turbo prior to me trimming it was ablout even with the far side of the elbow I welded on.  There was no way to make it fit short of how it was done in the pics...
Reply:Perhaps a silicone connector with a 90* aluminum elbow held together with t-bolt clamps would do the trick, preventing you from having to weld the compressor housing at all.  This website here has tons of stuff for fabrication.http://stores.channeladvisor.com/verociousmotorsportsIf you want to go V-band, this website here has aluminum V-band kits.http://vibrantperformance.com/catalo...bda82feaa8ebb4