A 3.4 DOHC Build then... F40 Turbo (Page 6/57)
Hudini FEB 18, 12:32 AM
Beautiful work. Missed the expansion joints earlier. Looks very good.
ericjon262 FEB 18, 12:36 AM
good job on the crossover, your's looks way better than mine does!
Will FEB 19, 11:20 AM

quote
Originally posted by Fierobsessed:

In the final install, I plan on wrapping the crossover tube with some "Lava Rock" header wrap. The crossover passes the charge pipe, the air filter and the turbo compressor housing. I need that pipe to give off minimal heat to the engine compartment. I might even make a metal shield to go around the wrap, or to shield the air filter and compressor housing I'll cross that bridge when I get a bit closer to finished.



I'd recommend ceramic coating inside and a metal heat shield vice the header wrap... Wrap really keeps the heat in the metal
fieroguru FEB 19, 12:38 PM
Great job on the fabrication and welding! Everything is displayed in a neat and orderly fashion.
Fierobsessed FEB 19, 09:43 PM

quote
Originally posted by Will:
I'd recommend ceramic coating inside and a metal heat shield vice the header wrap... Wrap really keeps the heat in the metal



I've thought a bit about ceramic coating. My fear is that if anything chips off, anything at all, it will damage the rediculously expensive turbine.

No matter what, I absolutely must keep the radiated heat to a minimum on the rear bank tube. The header wrap, with a metal shield is closest to what the factory used, except the temperatures may be quite a bit hotter in this setup, so I do have my concerns about it too.


quote
Originally posted by fieroguru:
Great job on the fabrication and welding! Everything is displayed in a neat and orderly fashion.



Thanks! I think we share the same love for fabrication! Might even over do it just a bit
fieroguru FEB 20, 07:16 AM
Not sure if there is room, but you may try to fit an intake tube to the turbo so the filter/air intake can be further away from any heat. The added benefit is you could do more to keep the intake tube cool (coated, wrapped, etc) without worrying about long term impact due the low temp that the tube would see. Then you could do less on the exhaust side.

Another option would be to add a few heat shields tacked to the exhaust. Something like these:
Fierobsessed FEB 27, 04:50 PM
Just got back from a little vacation, a few parts are on order and on the way. I'm waiting on a catalytic converter with 3" metal substrate, some more 3" pipe, an oil feed line, some fittings, a turbo blanket, 1.25" bend pipes and a piece of metal to make a flange for a new water outlet. Hope I don't run out of argon! I've still got a LOT of welding to do!

My next focus is on cleaning the cradle, clearancing it for the transmission, Then I will do the water outlet and the remainder of the exhaust.

Getting 3" to pass between the front engine mount pad on the cradle and the oil pan is really tight. It does fit, but only just. there will be a little bit of the exhaust below the bottom of the cradle, I've resigned to this fact, but it's no big deal.
Fierobsessed MAR 02, 07:35 AM
OK! progress report time!

Clean cradle... Check!


Cradle notching, and filler plate


Weld the bugger in (will clean up this rather crappy weld later)


Fit check shows that the notching was a bit excessive, but extra room is better then not enough!


Once that was done, the parts to build the new water neck showed up. I purchased 2, 304 stainless16 gauge 1.25" mandrel bent 180's one with a tight 1.8" radius, the other with a loose 3.6" radius, and I got a 4X6" piece of 1/4" 304 Stainless plate.



My original intention was to have the water outlet come out and make a sharp 90 up and the long radius to go around the turbo's air inlet. This is what the outlet looked like with the turbo and air filter in place.


After some careful reconsideration of that plan I found I could squeeze the pipe in going downward and run it under the turbo towards the coolant piping on the car. Much shorter, much neater. So I made a couple of cuts, and one weld, and this was what I came up with:


And in place,


Once I had a better idea of how the pipe needed to be run, I cut another piece of pipe, this time with the long radius and welded it to the first pipe.


Next was straight on to the flange.



A little fancy work with the sawzall and the belt sander


Drill some holes


Mount it up with the thermostat in place for the fitment of the pipe


I then put the pipe in place, first with a couple of tack welds, then I removed the flange and pipe and finished the weld.


Looks pretty good!


With the Air filter in place,


This is where it is exiting seen under the turbo, in front of the transmission


That is it for the water neck for the time being. I will have to come back to it to add a bleeder (filler too?) and one support, possibly add another pipe to it to bring it closer to the under car coolant tubes.

I also recieved a couple of other goodies. I got my oil line, 36" -4AN stainless braded line, with a 90 on one end, and a straight on the other, and my turbo blanket. It'll go in something like this:


I also recieved a 3" metal substrate catalytic converter. Honestly I'm a bit dissapointed with it. It's just so dinky I don't know how well it will flow. Its 3" inlet and 3" outlet, yet its only 4" in diameter! But being that it has a super fine metal substrate, I guess it keeps the bulkiness down to a minimum? I've decided that I will V-band the inlet and outlet into place. So If I hate it, I can change it out, or hollow it out for the dyno and put a larger cat in for the street... or whatever I want to do!
tesmith66 MAR 02, 07:55 AM
Just out of curiosity... what are you going to do with the old exhaust system?

------------------
1986 SE Aero coupe.

3.4 DOHC swap is complete and running, now just have to finish the rest of the car...

3.1 88FieroGT MAR 02, 10:41 AM
Very nice work you are doing... Just out of curiosity why didn't you run an divorced waste gate (meaning open to atmosphere)? Emission?