b6304f+t header progress thread!

the poi · 08-26-2005, 01:19 AM

Okay, since I started the header I guess I'll start a thread. Anyway, idea:

Parts:

First, cut all the bends to the right radius. 10 of the 20 bends are 90* so hey, easy. The other 10* are cut thusly:

200$ harborfreight bandsaw. fantastic!

Set the angle on the frame, tape the frame down. Set elbow in the "box" and clamp it down.

Fancy!

Holy macaroni!

Next up, straight pipes cut to length and I mark all the pipes with their mating angles. Then I simply weld it together!

thelostartof · 08-26-2005, 01:23 AM

it'll never work

looks pimp

own6volvos · 08-26-2005, 01:28 AM

So wheres your flange

*whistles*

jao · 08-26-2005, 01:44 AM

what? a band saw? you're cheating! j/k

looking good so far. what wastegate are you planning on running?

the poi · 08-26-2005, 01:49 AM

Quote:

Originally Posted by jao

what? a band saw? you're cheating! j/k

looking good so far. what wastegate are you planning on running?

a blue one!

linuxman51 · 08-26-2005, 02:24 AM

anyone else had issues with their tial creeping? mine creeps like a bitch in 4th, starts at 7, by redline its at 14 (this is a big problem when your injectors are at 135% DC by 6800 rpms). open dump no bleeder or anything, 7.5 spring.

sorry, thread jack. looks good, get er welded

the poi · 08-26-2005, 02:31 AM

Quote:

Originally Posted by linuxman51

anyone else had issues with their tial creeping? mine creeps like a bitch in 4th, starts at 7, by redline its at 14 (this is a big problem when your injectors are at 135% DC by 6800 rpms). open dump no bleeder or anything, 7.5 spring.

wheres the gate attached?

stylngle2003 · 08-26-2005, 02:49 AM

lookin good so far man, keep it up

adrianpike · 08-26-2005, 02:50 AM

It'll never...

...err...

...weld.

Gizmo · 08-26-2005, 02:56 AM

Spool. The word you're all looking for is spool. The exhaust manifold will never spool.

ND4SPDR · 08-26-2005, 03:11 AM

Quote:

Originally Posted by Gizmo

Spool. The word you're all looking for is spool. The exhaust manifold will never spool.

Looks good dude.

adrianpike · 08-26-2005, 03:23 AM

Quote:

Originally Posted by Gizmo

Spool. The word you're all looking for is spool. The exhaust manifold will never spool.

He'd have to get it welded first for it to never spool.

But it'll never weld.

Sp3aK · 08-26-2005, 08:00 AM

Looks hot man... When are you going to start releasing paddle shift kits? I'll mail you my car so you can test one on a 240 wagon

blkaplan · 08-26-2005, 09:25 AM

Looking good,

Sometimes simple methods can yield get products with some time thrown in for finishing work.

How do you plan to tackle the collector portion?

linuxman51 · 08-26-2005, 09:27 AM

Quote:

Originally Posted by the poi

wheres the gate attached?

collector...

Hank Scorpio · 08-26-2005, 10:20 AM

My tial was ALWAYS rock stable. +/- 1 psi.

What boost controller setup are you using (if any)?

Chris, make sure you use a flex joint on the downpipe and the wastegate (either before or after doesn't matter)

linuxman51 · 08-26-2005, 11:38 AM

Quote:

Originally Posted by Snoop Dougy Doug

My tial was ALWAYS rock stable. +/- 1 psi.

What boost controller setup are you using (if any)?

Chris, make sure you use a flex joint on the downpipe and the wastegate (either before or after doesn't matter)

i'm not, its supposed to be just gate pressure (7.5)

Hank Scorpio · 08-26-2005, 11:40 AM

Quote:

Originally Posted by linuxman51

i'm not, its supposed to be just gate pressure (7.5)

Thats bizare. Your not using silicone vac line to plumb it are you?

linuxman51 · 08-26-2005, 11:43 AM

Quote:

Originally Posted by Snoop Dougy Doug

Thats bizare. Your not using silicone vac line to plumb it are you?

no

the poi · 08-26-2005, 02:38 PM

Quote:

Originally Posted by blkaplan

How do you plan to tackle the collector portion?

the plan at the moment is to figure out some way to select the intersect fo the pipes out from the model. If all else fails, I know I can get a 3d sketch out of it. Then i gotta figure out some way to "unroll" the sketch into a flat drawing. Then I should be able print it, wrap it around the pipe, trace the contour, and cut it out. it'll work great if i can get it to work

rallyvovo · 08-26-2005, 05:00 PM

Nice SolidWorks model!

im just learning how to use it. then ill have access to machine galore. ill post up when i need to do a project for ideas on what to design/model. this is for school out at CU Boulder where another Tbrickers is also residing!

the poi · 08-30-2005, 03:48 AM

Alright, update time. Since the last update, I was preoccupied with a series of things. First, had to replace the starter in my dad's frontal-accident-victim project audi a4 (we've put no miles on the car, and the starter has gone. volkswagen!). Then we got to puttering it around, and I learned how to stall an audi a4. During this learning experience, I discovered the timing belt tensioner did not like being tight, and so it loosened it else. volkswagen!. After fixing that, I successfully learned how to drive stick (which is hilariously fun for some reason...I'm very conflicted now

). My brother later tried to learn how to drive stick. He succeeded in vaporizing the clutch. I forsee learning how to replace the clutch in a ****ing quattro a4 soon (****).

However, my greatest achievement actually had to do with this thread's topic. After spending quite literally over 10 hours in front of a damn 15" monitor, I figured out how to coax solidworks into doing what I wanted it to do. But that waits till later, lets get all the little things out of the way.

Firstly, cut all the straight sections, and cut 45* notches on the pipe ends for easy welding. All the pipes are now completely done, and ready to be marked, alligned, and welded. All assembled:

20 noodles and 4 straight sections. Nice shiny angle cuts on em.

Now, these I got, like, a few days back, but I don't recall posting them. Laser cut from 3/8" mild steel, the manifold flange was drawn up in solidworks, converted to DWG, and sent off to own6's former machine shop guy:

oo, sharp!

And now, as I alluded to earlier...

wait for it...

waaaaait for it....

Collector's done! First time this was assembled was no less than 20 minutes ago (with quite possibly the worst choice of bonding material imagineable, masking tape). With the exception of a little extra material on the front most "point", all the ****ing vertexes line up perfectly. And the little bits of inconsistency I attribute to my use of a rather ungainly angle grinder to cut around the marking, rather than the markings themselves.

Solidworks usage tip for those who give a ****--
It took ****ign forever to get working, but essentailly, each pipe is created as a sheet metal part--rolled into a pipe shape. Assembled the pipes in the main header assembly, and edited each pipe part in context--for each pipe, I started a 3d sketch, and dropped in the intersection curve from the neighboring pipes. Then I edited each part, and made 4 closed body sketches around the circumference of the pipe in the shape I needed cut out, and then made an extruded cut from that drawing surface in towards the center. Flatten the part gives a perfect "unwrapped" cutout drawing

(an be sure to kill any external relations int he drawings, when you go back to the assembly, the intersection curves tend to totally get hosed!) Then I just unfolded the parts, dropped them into a drawing, printed them, wrapped em around the pipes and cut em out.

Okay, chances are you've stopped halfway through that up there, but thats okay, this is the good part,

/\ this is the corner that needs a little encourgement. the gap and the other misalignment is actually being cause by a little point of metal on the nearest pipe-- ill girnd that off and it should fit perfectly

note how the vertices meet right up in both places

(this is modern art)

/\That would look better if that middle pipe wasn't hanging out in space, but eh.

In conclusion, the collector turned out several times better than I expected. I was planning on making a whole hell of a lot of mistakes but it came out better than I could have ever hoped. Only thing left now is to mark all the pipes with their mating angles, and then I can start taping everything together... and then I weld it....then I figure out where Im gonna put the wastegate and shove a pipe into the collector accordingly!

08-30-2005, 06:01 AM

looks awesome dude. well done.

love the HF bandsaw... how well has it held up for you? would you recommend it again?

how intuitive is solidworks? I haven't used cad in about 15 years so I'd be a little rusty.

more importantly...

when do you start welding?

Mike

CEHepp · 08-30-2005, 08:22 AM

http://www.pbase.com/765ti/image/45260821

Is that JB Weld holding your oil feed on?

Im going to tell you first hand that JB weld doesnt like much heat, and DEFINITELY not any oil! Be careful!

08-30-2005, 08:23 AM

08-26-2005, 01:19 AM	#1
the poi On a mission Join Date: Jan 2003 Location: Pasadena, CA	b6304f+t header progress thread! Okay, since I started the header I guess I'll start a thread. Anyway, idea: Parts: First, cut all the bends to the right radius. 10 of the 20 bends are 90* so hey, easy. The other 10* are cut thusly: 200$ harborfreight bandsaw. fantastic! Set the angle on the frame, tape the frame down. Set elbow in the "box" and clamp it down. Fancy! Holy macaroni! Next up, straight pipes cut to length and I mark all the pipes with their mating angles. Then I simply weld it together! __________________

08-26-2005, 01:23 AM	#2
thelostartof unbalanced chemical Join Date: Jun 2002 Location: Apache Junction, AZ	it'll never work looks pimp __________________ Chip Feedback Thread / PM Current Chip Prices / PM for DownPipe & Exhaust Price / Silicone Cooling Hose Sets 2/7/9

08-26-2005, 01:44 AM	#4
jao Board Member Join Date: Apr 2004 Location: AZ	what? a band saw? you're cheating! j/k looking good so far. what wastegate are you planning on running? __________________ -jesse 1971 142e 16v/MSNS/m47/18" Kinesis K20s etc 1988 244dl 16v+T/18" HREs/ corbeus / MSNS etc "...i often drift when i drive..." - the ghetto boys newest pictures here:https://www.facebook.com/pages/J9Fab/399942106768777 and lots of old ones here:www.pbase.com/jaodesign/jesse

08-26-2005, 02:24 AM	#6
linuxman51 ARRRRHARHAR Join Date: Dec 2002 Location: mont, AL	anyone else had issues with their tial creeping? mine creeps like a bitch in 4th, starts at 7, by redline its at 14 (this is a big problem when your injectors are at 135% DC by 6800 rpms). open dump no bleeder or anything, 7.5 spring. sorry, thread jack. looks good, get er welded __________________ "They bum rushed them in their own crib, they drank all their beer, they partied with their ladies and they left with the trophy" Megasquirt Tuning! Plug and play LH 2.4 Megasquirt, now with stealth mode! ported volvo heads

08-26-2005, 02:49 AM	#8
stylngle2003 Board Member Join Date: Nov 2002 Location: Two Up, Two Down	lookin good so far man, keep it up __________________ -Billy 1993 945ti "titebox" (DD) 1985 744GLE (perpetual +t project) 1996 Chevrolet Tahoe Vortec 2WD 1990 Mazda Miata track toy

08-26-2005, 01:28 AM	#3
own6volvos He who controls the Spice Join Date: Nov 2002 Location: Milwaukee, WI	So wheres your flange whistles

08-26-2005, 02:50 AM	#9
adrianpike There's a gif for that. Join Date: Dec 2002 Location: Bellingham, WA and Seattle, WA	It'll never... ...err... ...weld. __________________ I'm looking to buy the following - PM me if you've got any of it: B234 blocks & heads, 93 850 bumper, ford 8.8", T5 WC I am extremely offended and have blocked [someone]. - brett Adrian is omniscient, you will never escape his wrath. - 500dollar744ti doug was here

08-26-2005, 02:56 AM	#10
Gizmo Board Member Join Date: May 2005 Location: Brooklyn / North Jersey	Spool. The word you're all looking for is spool. The exhaust manifold will never spool. __________________ Evan 1996 850T - Bilsteins all around, a homebuilt MBC, Samcos, backcut SS valves, and R manifold, and an obscene amount of luck. Have owned: 1996 960 - Totaled

08-26-2005, 08:00 AM	#13
Sp3aK Board Member Join Date: Jan 2005 Location: Durham, NC	Looks hot man... When are you going to start releasing paddle shift kits? I'll mail you my car so you can test one on a 240 wagon __________________ Volvo defector. Hate me I drive a Honda. 91 Volvo - Sold but not forgotten.

08-26-2005, 09:25 AM	#14
blkaplan 50 shades of beige Join Date: Jul 2002 Location: Rockville, MD	Looking good, Sometimes simple methods can yield get products with some time thrown in for finishing work. How do you plan to tackle the collector portion? __________________ www.BEIGEPOWER.com Kaplhenke Racing Facebook

08-26-2005, 10:20 AM	#16
Hank Scorpio Chubfest 2009 Survivor Join Date: Nov 2002 Location: The neighborhood with the ******* guitar player.	My tial was ALWAYS rock stable. +/- 1 psi. What boost controller setup are you using (if any)? Chris, make sure you use a flex joint on the downpipe and the wastegate (either before or after doesn't matter) __________________ Will trade guitars/guitar parts for go fast goodies or stuff I need. Just PM. www.kauerguitars.com the second best way to upset neighbors and alienate people. History: Car 1 \| Car 2 \| Car 3

08-26-2005, 05:00 PM	#21
rallyvovo Board Member Join Date: Jan 2005 Location: Sea-town, Boulder for naww	Nice SolidWorks model! im just learning how to use it. then ill have access to machine galore. ill post up when i need to do a project for ideas on what to design/model. this is for school out at CU Boulder where another Tbrickers is also residing! __________________ :::: 9 series pimpin' ::::

08-30-2005, 03:48 AM	#22
the poi On a mission Join Date: Jan 2003 Location: Pasadena, CA	Alright, update time. Since the last update, I was preoccupied with a series of things. First, had to replace the starter in my dad's frontal-accident-victim project audi a4 (we've put no miles on the car, and the starter has gone. volkswagen!). Then we got to puttering it around, and I learned how to stall an audi a4. During this learning experience, I discovered the timing belt tensioner did not like being tight, and so it loosened it else. volkswagen!. After fixing that, I successfully learned how to drive stick (which is hilariously fun for some reason...I'm very conflicted now ). My brother later tried to learn how to drive stick. He succeeded in vaporizing the clutch. I forsee learning how to replace the clutch in a **ing quattro a4 soon (*). However, my greatest achievement actually had to do with this thread's topic. After spending quite literally over 10 hours in front of a damn 15" monitor, I figured out how to coax solidworks into doing what I wanted it to do. But that waits till later, lets get all the little things out of the way. Firstly, cut all the straight sections, and cut 45 notches on the pipe ends for easy welding. All the pipes are now completely done, and ready to be marked, alligned, and welded. All assembled: 20 noodles and 4 straight sections. Nice shiny angle cuts on em. Now, these I got, like, a few days back, but I don't recall posting them. Laser cut from 3/8" mild steel, the manifold flange was drawn up in solidworks, converted to DWG, and sent off to own6's former machine shop guy: oo, sharp! And now, as I alluded to earlier... wait for it... waaaaait for it.... Collector's done! First time this was assembled was no less than 20 minutes ago (with quite possibly the worst choice of bonding material imagineable, masking tape). With the exception of a little extra material on the front most "point", all the **ing vertexes line up perfectly. And the little bits of inconsistency I attribute to my use of a rather ungainly angle grinder to cut around the marking, rather than the markings themselves. Solidworks usage tip for those who give a -- It took **ign forever to get working, but essentailly, each pipe is created as a sheet metal part--rolled into a pipe shape. Assembled the pipes in the main header assembly, and edited each pipe part in context--for each pipe, I started a 3d sketch, and dropped in the intersection curve from the neighboring pipes. Then I edited each part, and made 4 closed body sketches around the circumference of the pipe in the shape I needed cut out, and then made an extruded cut from that drawing surface in towards the center. Flatten the part gives a perfect "unwrapped" cutout drawing (an be sure to kill any external relations int he drawings, when you go back to the assembly, the intersection curves tend to totally get hosed!) Then I just unfolded the parts, dropped them into a drawing, printed them, wrapped em around the pipes and cut em out. Okay, chances are you've stopped halfway through that up there, but thats okay, this is the good part, /\ this is the corner that needs a little encourgement. the gap and the other misalignment is actually being cause by a little point of metal on the nearest pipe-- ill girnd that off and it should fit perfectly note how the vertices meet right up in both places (this is modern art) /\That would look better if that middle pipe wasn't hanging out in space, but eh. In conclusion, the collector turned out several times better than I expected. I was planning on making a whole hell of a lot of mistakes but it came out better than I could have ever hoped. Only thing left now is to mark all the pipes with their mating angles, and then I can start taping everything together... and then I weld it....then I figure out where Im gonna put the wastegate and shove a pipe into the collector accordingly!

08-30-2005, 06:01 AM	#23
740ATL Guest	looks awesome dude. well done. love the HF bandsaw... how well has it held up for you? would you recommend it again? how intuitive is solidworks? I haven't used cad in about 15 years so I'd be a little rusty. more importantly... when do you start welding? Mike Last edited by 740ATL; 08-30-2005 at 06:22 AM.. Reason: can't stop looking at the collector...

08-30-2005, 08:23 AM	#25
740ATL Guest	- Last edited by 740ATL; 06-04-2006 at 07:06 AM..

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