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Gtir Motorsport club » General Discusion » Gtir related Discussion » Exhausts

Exhausts

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1 Exhausts on 25th January 2018, 8:52 am

DC313

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Hi All,

Just thought I'd share a few things I've been working on recently.

First up is an exhaust manifold with the turbo flange an additional 30mm away from the engine, but in the same orientation to aid clearance against the engine / bell housing when fitting large a turbo.

CAD design, jig and tacked together part.



I've also made the jig to suit standard exhausts.



I plan to put a brace inbetween the exhaust flange and the turbo flange to help support the turbo and so reduce the risk of cracking



The jig has a small hole in the turbo flange mount so I can purge the exhaust when fully welding it.



The manifold will also have a external wastegate with the pipe coming off the side above the turbo flange, which I'll cut in after



I've also drawn up all parts including a jig for a 3" elbow and started looking at the flow through them.



Cheers

2 Re: Exhausts on 25th January 2018, 8:58 am

mike74

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Looks really good mate, well done!
I wouldn't fancy drawing that manifold up in Solidworks or Inventor, that's for sure!!!!

3 Re: Exhausts on 25th January 2018, 9:04 am

DC313

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@mike74 wrote:Looks really good mate, well done!
I wouldn't fancy drawing that manifold up in Solidworks or Inventor, that's for sure!!!!

Thanks for the compliment!

Haha I'm a bit sad and love doing exhaust headers and rollcage work etc in solidworks, its not too bad once you've done a few Very Happy


4 Re: Exhausts on 25th January 2018, 9:53 am

Ryaneg6freak

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I really wish I could see these pictures Sad

5 Re: Exhausts on 25th January 2018, 10:41 am

mike74

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TBH I don't have to do anything using 3D sketches at work so haven't learned how to do them properly. Looks like a proper ball ache regardless!

6 Re: Exhausts on 25th January 2018, 12:19 pm

gtir_woody

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moderator
moderator
Mate this looks awesome, well done thumbsup

7 Re: Exhausts on 25th January 2018, 1:45 pm

Mr B

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gtir technician
gtir technician
That's cool progress.
Wish I was good with cad drawing software, makes me angry when see how easily some people draw these cad images .
I'm struggling with sketchup and generally use my own style CAD , Cardboard Aided Design .
Good luck with your manifold and elbow designs .

8 Re: Exhausts on 25th January 2018, 4:31 pm

shroom

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@Ryaneg6freak wrote:I really wish I could see these pictures Sad

Yeah I don't see them either looks like they are on photobucket

9 Re: Exhausts on 25th January 2018, 6:55 pm

Zia


That looks like a really nice manifold,the external wastegate will need to be at collectors,most manifold have it pointing towards the comp housing.would be interested in this manifold if you every want to do a batch of them.


Zia

10 Re: Exhausts on 25th January 2018, 7:03 pm

johnny gtir

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moderator
moderator
I don’t see them

11 Re: Exhausts on 25th January 2018, 7:31 pm

Ryaneg6freak

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Please god, no more photobucket hosting! Use the forum uploader lol.

12 Re: Exhausts on 25th January 2018, 8:32 pm

nomad

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Admin
Admin
I can't see them either....


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13 Re: Exhausts on 25th January 2018, 8:43 pm

DC313

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Sorry it was dodgy photobucket upload, I've been going off that site for a while now so good excuse to try postimage out!

Hopefully the pics below work... yes the external wastegate will come out just above the turbo flange towards the compressor, I would love to have it pointing downwards slightly to help the flow but just don't think there'll be room.

I could be tempted to make more if requested, but I've got a few other jobs to complete first...









Thanks for all the nice comments so far as well (for those that have been able to see the pics)



Last edited by DC313 on 26th January 2018, 7:01 am; edited 2 times in total

14 Re: Exhausts on 25th January 2018, 9:21 pm

johnny gtir

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moderator
moderator
Great work

15 Re: Exhausts on 26th January 2018, 7:03 am

DC313

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@Mr B wrote:That's cool progress.
Wish I was good with cad drawing software, makes me angry when see how easily some people draw these cad images .
I'm struggling with sketchup and generally use my own style CAD , Cardboard Aided Design .
Good luck with your manifold and elbow designs .

lol! Nothing wrong with abit of Cardboard Aided Design! It's still the best way to prove something out!

16 Re: Exhausts on 26th January 2018, 10:38 am

Ryaneg6freak

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Yea, I still got nothing lmao

17 Re: Exhausts on 26th January 2018, 11:38 am

Mr B

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gtir technician
gtir technician
^ move out of the desert lol . Must be a pain these days with that sort of data limits .

18 Re: Exhausts on 26th January 2018, 11:45 am

GTI-R US

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Management
Management
Very nice work so far thumbsup


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19 Re: Exhausts on 26th January 2018, 3:58 pm

Ryaneg6freak

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@Mr B wrote:^ move out of the desert lol . Must be a pain these days with that sort of data limits .

You have no idea. Thing is I can see Flickr pictures though, and ones uploaded by the forum, just not photobucket and others

20 Re: Exhausts on 26th January 2018, 4:24 pm

Welling_AL

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Great work & development - looks excellent - hope the finished product works well for you !

21 Re: Exhausts on 26th January 2018, 8:45 pm

nomad

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Admin
Admin
What size pipework and material and size of the elbow ?


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22 Re: Exhausts on 26th January 2018, 9:25 pm

DC313

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@nomad wrote:What size pipework and material and size of the elbow ?

The manifold is 1.5" nominal bore with 2.8mm wall, all the flanges are 10mm and all 316l stainless.

The elbow is 3" od 1.6mm wall 316l again with 10mm flanges

23 Re: Exhausts on 26th January 2018, 9:38 pm

Cosmic73

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Nice bit of CFD analysis there. At Cummins our analysis dept do this too, for exhaust manifolds they would also do some thermal fatigue analysis to show if there's potential for cracks at the welds,

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