Update.

Briefly, I wanted to update everyone that the manifold is virtually done.  It is just some cosmetic stuff left because I want it to be pretty.  LOL.  Our Corvette has been giving me fits since last weekend so I have been focused on that so we can run it at an event this weekend.  Nothing major is wrong, just an electrical gremlin in the steering column causing the fuel to cut out over 2mph.  The parts are inbound, and I think I can get back to the manifold now.  Hopefully everyone isn't too bored yet.

Exhaust manifold part 3

I'm still working on it, mostly just blending welds trying to get a seamless look.  Just a lot of unnecessary work, but I don't want it to look like a turd when I'm finished either.  I'll keep on top of the progress reports.

Exhaust Manifold part2

Well I didn't get done, but I am so tired I can't see straight anymore.  The only part left is the transition from the end of the manifold to the turbo flange.  The wastegate and rest of the manifold is completed and fully welded.  I think I'll pick up some metal this week for the transition piece and then it will just need to be cleaned up.  There isn't much room for the holset, but they are huge compared to a stock turbo.  Overall a manifold isn't hard to make.  The hardest part is making the end of the round tubing fit the rectangular T3 flange. 

Exhaust Manifold

I am making progress on the manifold.  I decided to go with a log style do to the limited room available.  It exits towards the front of the engine and will place the turbo at the right front corner of the car.  Since the body of the turbo is so large I had to remove the power steering reservoir bracket as well as the one for the headlight motor.  I guess that means I'm converting to fixed headlights.  I don't mind really as I was pondering that move to get rid of more weight.  I'm planning to use a full 3" exhaust from the turbo back and its looking like I will have the room.  The exhaust will sort of travel over the manifold while the wastegate pipe travels under the manifold reconnecting just above the starter.  All of the guestimations have been accurate so far.  If the success holds out I may have the time to get the manifold all assembled by the weekend. 

Picture contest is over

Thanks to everyone who voted!  However we didn't win.  Guess I will have to keep my day job...lol.

Motor mounts are back

I picked up the motor mounts from the powder coater earlier this week. The one that appears to be shorter is for the passenger side. Like I said before the drivers side needs a spacer at the engine in order to use a flat plate. You could also contour the plate on the engine side to get rid of the spacer, but that makes attaching the tube for the cross member more difficult.  Fitment on the passenger side is really close to the starter.  I didn't actually try to pack it in this tight, but it will leave plenty of room for the 3" exhaust.  Fitment on the drivers side is good also with plenty of room for the steering shaft.
To make these I made tracings of the original AAN mount by gluing card stock to them and cutting it with a ball peen hammer.  The same way you would make a custom gasket.  Then just move the patterns to some .250" plate steel and cut them out.  I created the feet with some paper and a compass while watching television.  Transfer the pattern to some .250" plate steel and cut them out.  Next I mounted all the pieces and positioned the motor with an engine hoist.  Using PVC pipe that was close to the size of my tubing I made some mock ups.  Its really fast to work and cheap to start over if it doesn't work out.  After that you just recreate them with your .120" chromoly tube and weld it all together.  It doesn't take any special equipment other than a welder to do this, just some patience.  Now I can drop the motor back in and start the exhaust manifold. 

 

  

 

Fund Raiser Alert!!!

Okay this may seem weird, but just to the right of this post at the top of the sidebar is a link to a photo contest that I entered. That great picture of Nina that you can see was taken by my wife Jenn. Top prize in the contest is 1000 dollars! That will buy a few more pieces for this project. So if you would, click the link and vote for us. BTW you can vote once a day until 5PM central US time on the 1st of March. Thanks!