Tial 38mm Adapter for M106 Manifold (11/21 update)

Brad D. · Post by **Brad D.** » Nov 19, 2010 9:22 PM

I like it!

George · Post by **George** » Nov 19, 2010 10:45 PM

Alright, got some sleep. Im going to ship this to andrew tomorrow. Ive got some photos of the finish welded product. Overall, im happy but not thrilled. Hopefully, it all fits. This was actually the second downpipe i built, ill show pictures of the failed unit. Bon soir.

paul burke · Post by **paul burke** » Nov 19, 2010 11:28 PM

Hey George, thats pretty damn spiffy!!!!!!!

Paul

mooseheadm5 · Post by **mooseheadm5** » Nov 19, 2010 11:34 PM

I'll take some pics once it is installed on Andrew's car. I would do it for him but this stupid ankle

Corner Carver · Post by **Corner Carver** » Nov 20, 2010 12:13 AM

Brad D. wrote:I like it!

X2

Oh yeah, looks real nice George!

cvillebimmer · Post by **cvillebimmer** » Nov 20, 2010 8:45 AM

Looks like I'll have to take Wednesday off for the install!

Thanks George, this is awesome!

Brad D. · Post by **Brad D.** » Nov 20, 2010 12:02 PM

Man all these sweet new turbo parts and all I get to do is to try to get my car drivable this weekend.

cvillebimmer · Post by **cvillebimmer** » Nov 20, 2010 1:06 PM

mooseheadm5 wrote:I'll take some pics once it is installed on Andrew's car. I would do it for him but this stupid ankle

You around on Wednesday? Come over, drink beers and supervise. I'll even pick you up.

cvillebimmer · Post by **cvillebimmer** » Nov 20, 2010 1:07 PM

Brad D. wrote:Man all these sweet new turbo parts and all I get to do is to try to get my car drivable this weekend.

What's wrong with your car, Brad?

mooseheadm5 · Post by **mooseheadm5** » Nov 20, 2010 1:10 PM

cvillebimmer wrote:
mooseheadm5 wrote:I'll take some pics once it is installed on Andrew's car. I would do it for him but this stupid ankle
You around on Wednesday? Come over, drink beers and supervise. I'll even pick you up.

That might work out. Depends on when I have to fix my sister's ignition lock, though.

George · Post by **George** » Nov 21, 2010 1:36 PM

More pictures:

(sorry for the quality, shop has bad lighting and my phone was covered in grease and dirt)

Andrew's original downpipe mocked up:

This allowed me to jig the exit on the downpipe where it mates up to the rest of the exhaust.

Andrew sent me two extra exhaust flanges. One to be used as a reference point and one to be used on the new downpipe. Ideally I will cut this off in the future and use a SS V-band from Vibrant.

Here is the start of fabrication for the downpipe;

Here is the downpipe fabricated without the re-circ:

An interlocking SS flex bellow was used. Non-interlocking flex bellows can fail and collapse under high heat. I've never had one of these fail.

Pipe to pipe is fuse welded (.065" wall thickness on the tubing)

Pipe to flange and pipe to flex bellow is with 316 filler.
Here is the original adapter that I made:

Basically this stuck the tip of the WG too far from the head and there was not enough clearance between the head and the inner fender. I've currently have the head off of my e34 and was able to attempt to test fit this on the car. It did not fit. Back to the drawing board.

I flipped the WG up using a schedule 10 90deg bend.

Made a little piping to re-circulate the WG exhaust back into the downpipe. Again, I used an interlocking flex bellow to allow for expansions in the WG tubing:

My welding helmet broke as I did the finish welding on the WG tubing. My face was smashed up against the window and it kept fogging up so it made laying down a decent looking bead pretty difficult. Damn cheap helmets.

Here is the finished product:

All in all, I just hope it fits and I hope it works well for Andrew. Wastegates do not last forever and I simply can't believe there are so many guys running around with 30 year old wastegate controlling their turbo. This should give Andrew added flexibility when Peter tunes his car.

A couple of notes:

The stock studs in the turbine housing are being replaced with shorter studs from McMcaster. The rest of hardware is being supplied. All the parts ship out tomorrow, I hope it fits!

T_C_D · Post by **T_C_D** » Nov 21, 2010 3:08 PM

Awesome job!

demetk · Post by **demetk** » Nov 21, 2010 5:04 PM

Just beautiful.

mooseheadm5 · Post by **mooseheadm5** » Nov 21, 2010 6:05 PM

Awesome work as usual, George!

Hit Man X · Post by **Hit Man X** » Nov 22, 2010 1:04 AM

awesome

Good & Tight · Post by **Good & Tight** » Nov 22, 2010 7:46 AM

Great welding, looks very nice George. Are you Greek?

marc79euro645 · Post by **marc79euro645** » Nov 22, 2010 1:04 PM

Really nice !
I wish I could weld like that

Jsanders · Post by **Jsanders** » Nov 22, 2010 2:44 PM

Very nice! I'd probably take one depending on price.

cvillebimmer · Post by **cvillebimmer** » Nov 23, 2010 1:10 PM

Wastegate adapter, wastegate and hardware arrived today. Test mounted while I was home for lunch and the WG clears the AC lines with plenty of room to spare.

Fingers crossed the downpipes arrive later today for install tomorrow and a road-trip to Richmond on Thursday.

Paul, I have the perfect supervisor's chair for you.

mooseheadm5 · Post by **mooseheadm5** » Nov 23, 2010 2:00 PM

I'm there!

George · Post by **George** » Nov 23, 2010 4:08 PM

Thanks for the comments guys. Lets just wait and see if it all fits together. Doing something like this with the car not right in front of me can be frustrating because clearance problems can arise.

Good & Tight wrote:Are you Greek?

Indeed. Only 50% though.

I actually didn't think anything would arrive until tomorrow.

Keeping my fingers crossed for everything going together smoothly.

Andrew, take a look through this: http://www.turbobygarrett.com/turbobyga ... oolers.htm

I stock the following intercoolers and have custom end tanks designed and usually in stock for the following:

753447-6004
753447-6005
753447-6006

I will need the car for this however.

My Aluminum welding aint so pretty

Brad D. · Post by **Brad D.** » Nov 23, 2010 4:35 PM

cvillebimmer wrote:
Brad D. wrote:Man all these sweet new turbo parts and all I get to do is to try to get my car drivable this weekend.
What's wrong with your car, Brad?

It's all fixed now. I had a bad center bearing causing a major vibration and I had both front tires go bad (ran over something unavoidable on the freeway) within a week. It's now back up and running and man, I didn't realize how much I missed it.

I can't wait to see the transformation of your car. These are some fine parts awaiting install. Dyno results are coming I hope.

George · Post by **George** » Nov 23, 2010 4:39 PM

Brad D. wrote:Dyno results are coming I hope.

And it damn well better be at 20psi

Brad D. · Post by **Brad D.** » Nov 23, 2010 5:41 PM

George wrote:
Brad D. wrote:Dyno results are coming I hope.
And it damn well better be at 20psi

This should be good...

cvillebimmer · Post by **cvillebimmer** » Nov 23, 2010 7:05 PM

Brad D. wrote:
George wrote:
Brad D. wrote:Dyno results are coming I hope.
And it damn well better be at 20psi
This should be good...

Dyno, yes. 20psi??? If Paul Burke gives the green light or George commits to helping with the rebuild, I'm all in. I need a better fall back car than the Ranger.

George · Post by **George** » Nov 23, 2010 8:55 PM

cvillebimmer · Post by **cvillebimmer** » Nov 23, 2010 9:03 PM

George wrote:

I can't see the pic, but I have some pretty good guesses.

Hit Man X · Post by **Hit Man X** » Nov 24, 2010 7:35 AM

<--------- jealous of your new hotness.

George · Post by **George** » Nov 24, 2010 8:46 PM

cvillebimmer wrote:
Brad D. wrote:
George wrote:
Brad D. wrote:Dyno results are coming I hope.
And it damn well better be at 20psi
This should be good...
Dyno, yes. 20psi??? If Paul Burke gives the green light or George commits to helping with the rebuild, I'm all in. I need a better fall back car than the Ranger.

Ironically enough, last I talked with Paul, we both agreed that this turbo was out of breath by 15 psi. I really think that once the downpipe is on the car, the cat is removed and you have the larger intercooler, you'll be quite happy with the performance.

At least you can drive the e24 back to Cville now.

T_C_D · Post by **T_C_D** » Nov 24, 2010 9:16 PM

George wrote:Ironically enough, last I talked with Paul, we both agreed that this turbo was out of breath by 15 psi.

I respectfully disagree. All you have to do is look at the compressor map. It's not rocket science. It's totally happy at 410-450bhp and 15-18psi. It never drops below 70% efficiency.

MyE28.com

MyE28.com

Tial 38mm Adapter for M106 Manifold (11/21 update)