My new build

Well since I sold off my blow through turbo 200 3 years ago I figured Iw ould start a thread on the new build.

Sadly I don't have many pics right now (all my parts are showing up in a few days)

This is for my Turbo 250 Crossflow build.

in this thread : viewtopic.php?f=3&t=65721

I built a sheetmetal intake. I am dropping it off for final welding next weekend.

Here is where I sit right now....







I mocked up my turbo locatoin and built a little "shelf" to bolt it to. I moved this over to my spare head on the work bench so I can start fitting up my bends (currently sitting at UPS waiting for me to pick up)

So the plan is this....

.57 trim Turbonetics hybrid (will pretty much be maxed out but had it leftover from my 200 plans.....will be going bigger in the future)

38MM TiAL wastegate

1.5" Sched 30 (yes 30) 304 SS weld ELS for building my header from and some 1.5" SS pipe

3/8" thick CNC plasma cut SS header flanges

APT Turbo 3" T3 outlet flange

3" to 4" SS transition section

Some 4" SS mandral bends for a downpipe (Yeah I am going big)

My turbo only has a 2" outlet on the compressor and I need to 90 it forward so I am considering doing a cast elbow welded on the housing. I have a couple sets of flanges being cut so I might just do a split log style header for now (since it will use minimal bends and take less work for fitting it all up) the other plan is to just say the heck with it and do a 6-1 merge collector. I will prob go pick up some 1.5" PVC to play around with a merge design and for making up mockup runners (using my weld els and some duct tape)

No plans for an intercooler (might look into an air-water or water injection) since there is pretty much no room up in front of the motor.

Stay tuned for the holiday weekend when I will have all kinds of goodies and 4 days to play!!

Looking good mate.Cant wait to see more.

I have everything here to start building headers...EXECPT for my stinking head flanges. shop is claiming they are gonna run them first thing tomorrow morning....

cool part is tha tI had to buy a big hunk of SS plate (2'x2'x3/8") from another shop since they had none (off road fab shop so they mostly work in mild steel adn aluminum) they want my leftovers for making some flanges themselves (they have a couple turbo powered drag trucks too) so they will cut them for free!!! I am having three sets cut so I can have a couple spares so I don't have to go through this again.

I also picked up my weld els from the UPS place. I also picked up some SS wire and filler rod for welding up the header (picked up the wire so I could tack everything together and then take the tig to it later on)

so if all goes well I might have a header coming together by the end of the holiday weekend!!

Current plans is a split outlet header that will merge together at the turbo flange to make kinda a split inlet.

some teaser pics.

My flanges got finished today. they are plasma cut and I think the torch was jacked up some (tilted one way)

but I can't complain....$80 for three sets of flanges in SS. It will get me by for now. I think a T4 based header will be inthe near future after I max out this T3/T4.

that thing is going to be so fast!!!

If you want, sign me up for a set of those headers. Gladly pay you for them. It might tip the balance in my war of the garage engines.

Too many engines, not enough cars.

I might sell this one in a year or two after I get the car running and on the road. Looks like I will be needing an upgrade to a large frame turbo to support my goals.

I am not too sure I want to make another one of these yet....been a real pain so far and I am not even done fitting the tubes up!!

fiddled with the header a little over the weekend and some tonight. Kinda stole some of an idea from SSheaders.com in using PVC. on #3 you can see a section I was fitting. I just cut it using a hacksaw, die grinder (with non-ferrous cutter) and a coarse 3" rol-lok disc. I think wrap it in paper and trace the same out and cut out it. then I wrap the pattern around my bulk pipe and trace it out. then I just use the plasma, angle grinder and die grinder to cut it out and final fit it to the spot it needs to fit in.





that last 90 that turns up I just tacked on to get a feel for it. the angle the 90 is rolled back will depend on the merge I build under the turbo flange and also needs spaced out from the motor some (just didn't feel like getting that far on it yet)

Well I got bored tonight and kinda had set the goal of having a header by the end of the weekend....



Got most of the rest of it fit up tonight. I need a short piece on #5 still but can really get most the rest of the header done before I fit and weld it in. Just as a warning my welds look like crap right now. I am not back purging, using too small of a filler rod (1/16" and really should have grabbed 1/8"), using the wrong shield gas (I had just filled my tank not too long ago with regular CO2 mix and really shoudl have a tri-mix gas) and I am using a $200 Harbor Freight TIG (just a single knob for current control....no foot pedal.....and scratch start....contaminats the tungsten like no tomorrow) I am just getting root passes in for now and will have to run over them next week with a heavier rod (since I doubt TSC carries SS filler rod in Dayton)



well here is the dirty porn.

No eeee...gads goin' on here. Looks good.

That scratch TIG is going to cause you problems. I've heard of ways of minimizing the contamination but I'm not sure exactly what that's about. I've had very good luck using solar flux-B. It worked better for me than back purging and its not very expensive. Burns Stainless has some welding tips. Straight argon is what you want to use for TIG unless the scratch TIG requires something different. The CO2 MIG mix will definitely cause you problems. I think the 3/32" rods would be a better choice than 1/8". The 2% thorated tungsten seems to work best. There again I'm not sure what the scratch TIG requires.

Nice to see another turbo Ford 6 going together.

well I had a couple spots where I needed some gap filling abilities so I used the MIG on them. Up until then I had only been tacking with it. It welds a little nicer looking but lots of splatter.

I am trying to get this all welded up this weekend so I will just have to make do with the 1/16 rod. Looking around I am seeing some posts saying this HF TIG is a lift start so kinda have been trying to figure out a good way to get the arc started on it. I think the combonation of no back purge and the wrong gas is leaving me with these rough looking welds. I have TIG's before on a nicer Miller machine with a foot control and have been able to produce OK looking welds (no row of nickles but better looking than these) def will have some grinding ahead of me here.

Not my first turbo fordsix but my first turbo EFI aussie motor

CobraSix":19hzx4ja said:

If you want, sign me up for a set of those headers. Gladly pay you for them. It might tip the balance in my war of the garage engines.

Too many engines, not enough cars.

Click to expand...

I do have enough bits leftover to make a second one (well I am short a turbo flange but that is no biggie to get)

I might consider doing one. Price is dependant on the finish you want....as welded or ground smooth and everything blended.

Shoot me a PM if you are interested.

Made some progress today but not as much as I was planning. had to run some errands and do some laundry so I had to stay clean part of the day.



Pix









I think I might be able to finish the merge section tomorrow and maybe get the two halves welded together. I am not going to do a split inlet on this header and the wastegate will pull off the front right under the turbo flange.

made some more progress tonight. I need to finish up the collector area and do a little more grinding and blending but by the end of the weekend I should be there. I think before I weld the flanges on I will bolt them to my stock iron manifold and run a drill through them all to make sure they are lined up adn bolt it to the head and go to town welding it.

That looks so sexy! I like it. Congrats!

My 3.3L turbo motor is done but I have not started on building turbo header or rebuilding the T3 yet.