UrS4 exhaust manifold and more...(56k warning)

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Finally got to work on something that was mine, instead of building cool stuff for other people all the time...Figured it was time to get this old Audi really movin'.Car is:1994 Audi S4 (1 of 1400 or so sold in the US in 1994)engine: inline 5cyl, 2.2l 20valve single turbo, AAN engine codeMod list:  to much to list...Materials used:1018 cold rolled steel (header flange)1.50sch10 304SS weld elbows(manifold)1.50sch10 304SS straight tubing(manifold)4inch T6-6061 90degree bends and straight tubing3inch T6-6061 90degree bends and straight tubing2.75inch T6-6061 90degree bends and straight tubingWelding consumables used:1/8 ER4043 alcotec rod3/32 ER4043 alcotec rod1/16 & .035 ER308L Midalloy rod3/32 & 1/8 1.5%Lanthium tungstenArgon gas, for shielding and purge Machines used:-Lincoln Presision Tig 225Weldcraft WP-20 torch with #6 gas lens for all stainless welding, standard #6 cup for aluminum welding-Harbor Fright vertical/horizontal metal cutting bandsaw with Morse blades-Flow 4800 flying bridge waterjet-5axis CNC laser (work was outsourced on this machine)On to pics:Had the head flange designed in AutoCAD, fine tuned in Alibre12:Getting cut:1inch straight tube welded onto the head flange to make things a little eaiser:Collector all welded up:This is how I had to position the turbo:Most of the runners all done:2002 VW Golf TDi1994 Audi S4
Reply:All of the runners done:Perrin Intercooler that I modified to work for this application:2002 VW Golf TDi1994 Audi S4
Reply:Downpipe fitment:Downpipe all done:Exhaust all done, and yes it's aluminum, and yes, It's been done before Pile of parts:Last edited by LowlyOilBurner; 01-29-2010 at 08:57 AM.2002 VW Golf TDi1994 Audi S4
Reply:Everything installed:Really nice piece of aluminum:Really nice piece of aluminum with something really expensive bolted onto it:Last edited by LowlyOilBurner; 01-29-2010 at 08:54 AM.2002 VW Golf TDi1994 Audi S4
Reply:And I really don't know why these pics are so small, they are fine on other sites?2002 VW Golf TDi1994 Audi S4
Reply:what type of stainless did you use on the headers?  321?   that doesn't look like 304.BTW....I like this project!!  turbos and engines.....good stuff!
Reply:looks like funUA Local 598
Reply:Originally Posted by BurningMetalwhat type of stainless did you use on the headers?  321?   that doesn't look like 304.
Reply:nice setupsyncrowave 180 sd
Reply:what welding technique did you use, looks almost robotic or like a small orbital or alot of skill, very nice!
Reply:Originally Posted by kenklingermanwhat welding technique did you use, looks almost robotic or like a small orbital or alot of skill, very nice!
Reply:VERY nice workTim Beeker.
Reply:Originally Posted by LowlyOilBurnerI held the tig torch in my left hand and filler metal in my right, lol!
Reply:Originally Posted by LowlyOilBurnerIt's 1.5sch10 304SS.
Reply:They are locally sourced "weld els".  Prolly the same crap Vibrant sells, "Alfa Laval" brand or something.  The downpipe is .065 304ss.  409ss, no thanks.2002 VW Golf TDi1994 Audi S4
Reply:Tilton makes good stuff, we always ran their master cylindersMechanical Engineer
Reply:are you relaying solely on the header to support the weight or that turbo ?-Graham-Mechanical EngineerAutosport Mechanic/Fabricator
Reply:It will be braced.2002 VW Golf TDi1994 Audi S4
Reply:Very nice work. Is that the 4294 or 4202?  I have the 4294R on my DSM with the same Tial turbine housing and wastegate you chose. Also did the same combo with SS downpipe and AL downpipe-back in 4".The stainless on the downpipe it looks like you just fused except for the outlet v-band, correct? Probably could turn the heat down a hair, and up a cup size or two. The aluminum welds are really good I must say. What did you end up doing for hangers and muffler then?
Reply:Impressive fabrication.How are you upping the fuel and controlling the boost pressures on that monster?
Reply:Originally Posted by LowlyOilBurnerCar is:1994 Audi S4 (1 of 1400 or so sold in the US in 1994)engine: inline 5cyl, 2.2l 20valve single turbo, AAN engine codeMod list:  to much to list...
Reply:How much for an exaust set up? I'll send you the cat and muffler.Lonnie, 1993 S4
Reply:Also interested in a downpipe. Let me know if you're interested. I'm in Northern California. Awesome S4 by the way, I just got mine with only 108K miles. Stage 1+ chip package going in today from 034 in Fremont.
Reply:Originally Posted by 91TSiGuyVery nice work. Is that the 4294 or 4202?  I have the 4294R on my DSM with the same Tial turbine housing and wastegate you chose. Also did the same combo with SS downpipe and AL downpipe-back in 4".The stainless on the downpipe it looks like you just fused except for the outlet v-band, correct? Probably could turn the heat down a hair, and up a cup size or two. The aluminum welds are really good I must say. What did you end up doing for hangers and muffler then?
Reply:Originally Posted by LowlyOilBurnerGreat project.Thanks for the post. Keep it coming. Fairly nice welds and fab work.
Reply:Nice build...I have been around these kinds of builds a lot. I have to friends that own 2 different turbo shops...You sure aren't skimping any where. tilton clutch and all nice work !JerodHypertherm 30Miller Syncrowave 200Millermatic 140and a propane torch and hanger if all else fails
Reply:I guess I am not the only motorgeek over here! 20v ruleCarlohttp://public.fotki.com/Naudi2U/
Reply:That's a nice CQ, I always wanted one. I had a 90 20vq but I always liked the coupes
Reply:Not mine it is what I want mine to look like if I ever get to that point.Carlohttp://public.fotki.com/Naudi2U/
Reply:Absolutely amazing job. What are the details on the engine build and turbo? As an Audi Tech, I don't see to many 20v engines anymore. Our labor rate is too expensive for most of the owners (120/hr)....