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Old 11-30-2018, 12:28 PM   #1
LeedomtoFreedom
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Default Birthing a custom manifold with 120v welder

I'm a pretty decent shot on my peashooter 120v welder and wan't to make an exhaust manifold that's better flowing than a 90+

I'm obviously just worried that the welder won't penetrate the thick parts like the flange to the head. I could get a thinner flange but that can get too thin too quick. I don't have access to any 240v welder because my old highschool doesn't want me using their equipment anymore (liability)

Wondering if anyone's done it, if it's even possible. Most likely would add a support bracket because the hx35 is pretty heavy on it's own.
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Old 11-30-2018, 12:39 PM   #2
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Bevel all your joints, crank the voltage, it'll be fine.

What size wire are you using?
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Old 11-30-2018, 12:40 PM   #3
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Preheat will be your friend. Heat parts to 150-200 degrees, then weld. Won't be a problem with 120V welder and 1.50" Sched40. Bevel all of the weld connections, and have the flanges bolted to a cylinder head/turbo while welding those areas to prevent warping. Get it done, post pics.
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Old 11-30-2018, 01:12 PM   #4
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Quote:
What size wire are you using?
.8mm wire which seems to work fine but I don't think I'd go any thicker.

Is there any flange blanks for a 16v head or like what's the best way to do that. I could get my machinist to make a flange possibly but if there's something out there then why not use that. I'll look around but if anyone knows of one offhand then that works too.

I'll be sure to document the pristine workmanship of my manifold so everyone can learn from my mistakes.
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Old 11-30-2018, 01:20 PM   #5
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Josh/YoshiFab can probably still supply manifold flanges
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Old 11-30-2018, 02:14 PM   #6
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or find the correct CAD file (the files are here somewhere) load file to a disc and take to your local water jet shop.
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Old 11-30-2018, 02:43 PM   #7
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I built mine with a 115v dc tig. Just pay attention to your bevels. When it comes time to do the flange, bevel the id of the flange, and tap pipes into them until the bevels are hellafrush.
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Old 11-30-2018, 11:27 PM   #8
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Quote:
or find the correct CAD file
I'll have a look for it. Is there a CAD files for 16v section around here.
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Old 12-01-2018, 01:11 AM   #9
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I have both the 8V and 16V .dwg files.

PM me your email and I'll send them to you.
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Old 12-01-2018, 12:36 PM   #10
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I'm about to do a whole 16v swap with HX35 and probably some custom stuff involved.

Would the forum benefit from some decent documentary work on this?
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Old 12-02-2018, 12:32 AM   #11
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My welder sucks too, so oven or a propane torch help.
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Old 12-04-2018, 04:03 PM   #12
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Another question. Has anyone taken a prebuilt mani (doesn't even have to be for a b230ftk16v) and cut and welded a flange that matches?

Just a weird thought. If you think it's psycho then say so
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Old 12-04-2018, 04:21 PM   #13
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People do that with those eBay manifolds?
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Old 12-05-2018, 04:47 PM   #14
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Yeah you gotta brace em too they're prone to cracking
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Old 12-05-2018, 05:12 PM   #15
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Originally Posted by LeedomtoFreedom View Post
Another question. Has anyone taken a prebuilt mani (doesn't even have to be for a b230ftk16v) and cut and welded a flange that matches?

Just a weird thought. If you think it's psycho then say so
The ford 2.3 turbo manifold is similar but I don't know how it would fit with a 16v. The spacing of exhaust ports is very close. This is something that I've consider as well but haven't had a chance to do it yet.

Link to one on ebay.

https://www.ebay.com/itm/1979-1993-2...8cHf:rk:3:pf:0
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