Need some ideas on turbo header....

[Anonymous]

Ok....ive posted something earlier last fall about how my turbo 300 is going in my F 250. Ive got all parts and everything planned out and ready to bolt together except for the turbo header.

This header is going to be made out of stainless 304 schedule 10 pipe elbows in a combinnation of 90 degree, 45 degree, anbd straight sections.

Now that the beginning of the new semester for college is underway, thing are slowed and i dont have time to actually DO anything to it. But thinking about it and more palnning and asking of questions will make headways somehow.

I have a 3/8 stainless flange plate cut out to bolt to the head and a plate for the turbo side as well. I need to collect all 6 tubes into that small area of a T04B collectin area. i know some plating will have to be used, but i want to cut and weld them together at the collector to keep the overall width of the collector smaller (i dont want to have to have a 8 inch wide collector going into a 3.5 half in ch wide collection area)

So, i need som ideas as to mocking up in order to cut the elbows at the right areas so that when i weld them together, they will butt up flush and smoothly (for the most part) coincide with the others to form a nicely collected header. (look at turbo collectors at www.burnstainless.com to see what im talking about to pcture it) I want o do it like that, but i know my tools arent as sophisticated to do it THAT nicely, and THAT quickly.

I believe i can do it, i just have to go about it the right way to make it work. Anything you guys can think of or suggest will be of much help.

Thank ya.

 

[benwantland]

www.burnstainless.com

you might want to add the extra "s" in the middle to make it www.burnsstainless.com or it will go to a junk dummy search page.

 

[Anonymous]

ooops..sorry...yes..correct

 

[boston774]

I love the Burns page for the Inconel pipe. Nice stuff they have.

"Please call for pricing"



To paraphrase Commodore Vanderbilt - "If you have to ask, you can't afford it...."

 

[Thad]

Tigged Inconel on Apollo Project---- fun. Best in a glove box with inert atmoshere.

There is no need to attempt to equal length a turbo header. Being under pressure there is no scavenging . Just nice smooth bends avoid restriction. Some go so far as have the main section increase in diameter as each cylinder branch joins.

The are a couple turbo'd 250 on here that are good examples.

 

[Anonymous]

they wont be equal length, but liek you said Thad, i want to basically narrow themn down as each one goes into the collector. Just wondering on ways to cut the metal or to mock it up ingeniously so that it makes this easier to put together.

It doesnt help that Trial and error isnt an option. Stainless is expensive, so i want to do it once.

I was thnking of doing it with some plastci pipe, but the elbos and the OD sizes are different that that of sch. 10 pipe.

 

[JP]

It will be a challenge to say the least. I had two drawings done with the miter angles required for a 3 into 1 collector and 6 into 1 collector but no machine shops wanted to work with .065 wall tubing. Hydrojet wont work even with a solid insert while cutting. Wire EDM was the ultimate but the cutting price was equal to a burns finished product. So if you figure out a solution let me know, short of purchasing a milling machine.
Sorry I cant be of more help.
Just a thought a belt sander would probably do the trick if the belt stays flat to minimize fitment distortion.
jp

 

[Anonymous]

well i actualyl have a milling machine/lathe. it small, but i make things work often on it.

the header will actualyl be like two 3 into 1 collectors.

I have an autoCAD drawup of how it is going to be. its not 3D, but it shows the placement and orientation of how they collector and header flange are positioned and how the pipes collect.

I need to figure out how to post it though, as i do not have anywyas of posting it.

Ill be willing to email a copy of it...it will be in .dwg form. so you will need a viewer or AutoCAD to view it.

 

[Anonymous]

Have a look here http://bsdi.ath.cx/truck/ I think the last 3 shots are of a fairly compact well designed header. No piddling with any wierd 3 into 2 into one stuff or tapering tubes, just what looks to be a pile of very fancy fitting.
Pretty doable for a fellow with some patience.

 

[fastback69]

I'm going to turbo my 4.9 as soon as I finish my other project (69 fastback Mustang). I think a 2 x 3-into-1 headers is the way to go. Keeping the banks seperate will allow the use of a divided tangential turbine housing which has better exhaust flow and better response than a undivided tang or on-center. This will improve the spool time. I would like to see max boost below 2500 rpms to make it more fun. I'm thinking a 60-1 or 60-1 Hifi (preferably ball bearing) with a divided tang tubine housing, P-trim, with a .63 or .68 A\R.