building an inlet manifold?

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Hi there great forum by the way. I did a search before but couldnt find what i was looking for.I started tig welding about 6 years ago using an ESAB 180 AC/DC handy tig at work and worked on some of my friends projects. Here`s some of my work. Now im starting my own project and im on the UK market for a tig of my own i have about £1400 to blow. I need to know if there is a better tig on the market now with more features that can produce a better weld, or is it me that is lacking in skill.I was looking at this.http://cgi.ebay.co.uk/AC-DC-Squarewa...QQcmdZViewItemI have to weld togather theseand i wand a very good weld appearance like thisWhat do you think??Cheers in advance.If you ate yourself would you dissapear or double in size!
Reply:I just found this info about the ESAB handy tig i used to use."AC-balance and AC-frequency are set at the factory to suit the most common applications, making the unit ready for use without further setting up"This cant be good??If you ate yourself would you dissapear or double in size!
Reply:I´d say is the experience....being ESAB a nice brand...I´d say you should practice more, and ask someone with experience...Many Good AL guys in here....My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:So does anyone know how the AC balance and AC frequency is supposed to affect the weld?If you ate yourself would you dissapear or double in size!
Reply:Originally Posted by gnutz2So does anyone know how the AC balance and AC frequency is supposed to affect the weld?
Reply:AC balance affects the cleaning and/or penetration properties of the A/C wave. As the wave travels from "straight" to "reverse" polarity, adjusting the balance control will alter the percentage of "on" time for either polarity.The more Straight polarity (higher numerical value on control knob) the more penetration you get.The more Reverse polarity you have (Lower number on the dial) the more cleaning action you get to remove oxides from the surface of your work.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Originally Posted by ZTFabAC balance affects the cleaning and/or penetration properties of the A/C wave. As the wave travels from "straight" to "reverse" polarity, adjusting the balance control will alter the percentage of "on" time for either polarity.The more Straight polarity (higher numerical value on control knob) the more penetration you get.The more Reverse polarity you have (Lower number on the dial) the more cleaning action you get to remove oxides from the surface of your work.- Paul
Reply:Normal AC is balanced, that is half the time it is DC (-) and half the time it is DC (+).    The AC balance control allows you to adjust the percentage of the time that is electrode negative (DCEN) or electrode positive (DCEP).In DCEN the electrons flowing from the electrode to the work cause the maximum heat transfer to the work and result in deepest penetration.In DCEP, electrons leaving the work have the effect of breaking up and removing surface oxide, refered to as "cleaning action", but now the electrode is receiving the maximum heat input and thus less current can be tolerated without melting.AC balance allows you to control the balance of cleaning action and penetration.The AC frequency adjustment affects the stiffness and concentration of the arc size.  Lower frequencies give a broader softer arc, while higher frequencies concentrate the arc.  The concentrated arc may be helpful in getting fusion down in a tight joint, like in the corner of a fillet weld,
Reply:Originally Posted by zapsterthanks doctor!!  ...zap!
Reply:Hey Pulser.....JINX!! - Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Originally Posted by ZTFabHa ha ha...anytime buddy!!! As far as the "Intensity" control is concerned, a low setting will give the arc a broader, softer shape and a high setting will give it a more concentrated arc.I run my HF at full intensity as it seems to help with arc wander.- Paul
Reply:Thank for the thread Zapster. your IM looks great do you use a foot pedal or a remote and what amps were you welding at?If you ate yourself would you dissapear or double in size!
Reply:Originally Posted by gnutz2Thank for the thread Zapster. your IM looks great do you use a foot pedal or a remote and what amps were you welding at?
Reply:Ok an update.i`ve been buying tig welders and using them since my last posts and i can definately say that my welding has come on leaps and bounds thanks to the advice on this forum.i purchased a mitech 200 amp AV/DC tig from china and im very pleased with the machine.heres some pics and i have a few questions too.im getting on with my car now and have fabricated a fuel tank and started on the fuel rails and the inlat manifold.The problem is as you can see in the pictures there is contamination in the welds, its not a great deal but it`s annoying me nonetheless. It only seems to be happening when im starting to weld but i am using pre flow gas and post flow gas and ramping the current up and down, also the tip is turning a dark brown colour instead of a mirror finnish ball like whan i use the tig setup at work.Any suggestions, Baz?If you ate yourself would you dissapear or double in size!
Reply:I don't see very many 'brush tracks' where the welds are... brushing with acetone and a SS brush to remove the crud.Kudos for building your own intakes.  Looks good.On a side note... what kind of vehicle?  I notice the odd number of cylinders.
Reply:I did wipe everything down with thinners to remove any muck but did not use a SS brush.Do you have any idea why the tip is turning a burnt coulor? because other tigs ive used the tip has a mirror finnish on it??The car was a 1.3 mk2 golf but now has a 2.2 20valve 5 cyl turbo engine with about 550hp and a 6 speed audi quattro 4wd transmission If you ate yourself would you dissapear or double in size!
Reply:Originally Posted by gnutz2I did wipe everything down with thinners to remove any muck but did not use a SS brush.Do you have any idea why the tip is turning a burnt coulor? because other tigs ive used the tip has a mirror finnish on it??The car was a 1.3 mk2 golf but now has a 2.2 20valve 5 cyl turbo engine with about 550hp and a 6 speed audi quattro 4wd transmission :cool2:
Reply:Thanks, i`ll try all of these things but im not sure i know what you mean about the gas lens cup?If i didnt have one of these on the gas would go evreywhere, unless you mean use a bigger one.Finnished the fuel rails now and the tip still burns a brown colour but the welds seem to have little or no contamination. If you ate yourself would you dissapear or double in size!
Reply:Originally Posted by gnutz2Thanks, i`ll try all of these things but im not sure i know what you mean about the gas lens cup?If i didnt have one of these on the gas would go evreywhere, unless you mean use a bigger one.Finnished the fuel rails now and the tip still burns a brown colour but the welds seem to have little or no contamination.
Reply:In the end i did find out what was wrong, very simply i did not have the post gas going for long enough.This explained how only the start of the weld was contaminated and the tungsten looked like it was burnt.Anyway here is a video of the car in action and btw the first two manifolds i built blew up so i'm on the third one now.[ame]http://www.youtube.com/watch?v=BBiFgEdgQZk[/ame]And some pics of the latest maniIf you ate yourself would you dissapear or double in size!
Reply:Originally Posted by zapsterbeats me...i have a hobart..and i have figured out that if i have my "intensity" dial set the same as my heat setting i get a more stable arc..the welds look good..but on the intake plenum you need to slow down and space your "dips" a little closer..heres a ford manifold i did.. http://www.weldingweb.com/vbb/showthread...take+Close-Upsstudy these and you'll see what i mean.. ...zap!
Reply:Damn Son... I'm impressed... Congrats on getting your issues straightened out. Your fit and finish work looks top notch    BTYWhat are you using for engine management? I think I saw a dual injector setup... Again Very Nice
Reply:when you can get over 1000 hp per piston like a v8  let me knowmoney for hp you can not beata v8 Attached ImagesLast edited by ed mac; 02-20-2009 at 09:01 PM.
Reply:that is bad azz!!!!! or the dogs bullocks as you guys say.  like to see other mk2 owners on here also.  how do you get past mot on that?  any ways, I have nothing to add on the welding tips but zapsters know his stuff.Last edited by Stone_Elvis; 02-21-2009 at 12:20 AM.Reason: profanity, sorry
Reply:in school we used EWZr. Apparently its more resistant to aluminum contamination, and it keeps the balled end better.If your electrode is oxidizing, you need to increase your shielding gas flow. Your start/ends being contaminated are probly from this problem. Is your TIG power source HF? or scratch or lift start? are you sure you aren't inadvertently dipping the electrode in the puddle?So your other ones blew up? Got pictures of the destruction? How much PSI is your turbo feeding that manifold?Last edited by jamz; 02-21-2009 at 12:49 AM.Reason: more stuff.Originally Posted by ed macwhen you can get over 1000 hp per piston like a v8  let me knowmoney for hp you can not beata v8
Reply:Originally Posted by makoman1860?????? What the heck does that mean??????????HP per piston?? I dont see the metric here.
Reply:Originally Posted by jamzAll of a sudden its become a V8 vs I4 flamefight, dont worry Ive seen 4cyls put out 1khp/cyl too, woopty doo.
Reply:Originally Posted by ed macwhen you can get over 1000 hp per piston like a v8  let me knowmoney for hp you can not beata v8
Reply:Nice work there!I have done much work with the audi 20v 5cyl as well.Here are a couple pics of a manifold a recently did:
Reply:Sexy bag of snakes there.I built one header for a 10v 5cylinder with a big Holset HX-35. Don't think I have any pictures of it though (wasn't very pretty anyway being built from SCH40 and a MIG)
Reply:I`ll second that, nice exhaust mani.What diameter tube did you use?I used 48mm od tube, some would say too big but you get a nice step from the exhaust port to combat reversion and the lag is not bad at all.And the inlet manifold that blew TBH it was my fault because i had the nitrous injecting when hitting the rev limit.If you ate yourself would you dissapear or double in size!
Reply:And what point was that V8 guy trying to get accross.What a crank.If you ate yourself would you dissapear or double in size!