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Thought i would make the effort to share this as it demonstrates a simple way to achieve what appears (at a glance) to be a fairly complicated pieceThis is what we had... I was asked to replace this part of the manifold as (aside from being crap) it was too short because of the new, larger turboBecause the new piece was going to remain removable there was a large difference in port areas (and shapes) between the two flanges. A quick measure up showed i had go from a just under 3" at the secondaries to around 2.4" at the turbo flange. Sectioning and reshaping a 3" 90* bend seemed the easiest route so first step was to make a cut through a bend and 'clock' it to sort the offset...A quick look at the 'quality' of the port matching achieved by the origonal fabricator Right, time to work out where to section the bend so i can achieve a smooth transition between ports... First mark the centre line of the bend before laying out the 2 sections (1 per side) to be removed- cut lines match the bends CLR. Add a bunch of autogenous tacks and it's time to grab the angle grinder. Sectioning the bend this way obviously means that the ID of the bend will come up short- this is why the flanges have been left out of the equation so farOf course at this point the customer decided to eliminate the bolt together flanges at the secondaries- would've gone about this a completely different way if that had been what was wanted from the outset. Oh well...
Reply:This is what we have after a couple rounds of tinbashing and tacking (45* 3" for comparison)... An extra piece has appeared due to the deletion of the secondaries flange, more visible in this pic...which shows we're pretty much there, just a bit of planishing to do before fitting the wastegate pipe and final welding.Got a bit carried away with the work and forgot to take more pics. The elbow was fitted through the turbo flange, tacked where it touched (the straight sections) before persuading the corners to conform fully. Normally i would just weld it around the ID (no distortion worries) but as i was reusing the old flange (opened out to compensate for the pipes wall thickness) i welded the visible side as it hid some of the previous mess- easier and faster than removing it as there was some pretty deep undercutA bit of tube coping to fit the wastegate, set up a purge and some CJP welds and we're done...
Reply:Looks good...Escort?
Reply:nice work ChuckASME Pressure Vessel welder
Reply:Wow, nice solution to a complex problem.
Reply:Is that a twin scroll hot side ?....only asking becasue the original up pipe looked as though it incorporated two runners..nice fix -Graham-Mechanical EngineerAutosport Mechanic/Fabricator
Reply:Looks great.
Reply:Cheers all.Smokeshow, IIRC he said it's an early 3 door Sierra RS Cosworth- all i've seen of it is the bits pictured and a sketch with a few measurementsGraham, the origonal piece did indeed use two runners. This turbo is a single scroll, no idea what the old set up was
Reply:Thats an elegantly simple solution and looks good Hotrodder.(Funny how the blokes that know what they are doing always make it look easy and simple )A good guess is better than a bad measurement |
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发表于 2021-9-1 00:18:44