zetaboostboy522bhp

hi , well its all been pretty quiet on the western front with the bodyshell as jims not doin anymore work on it until the start of april. so ive been really busy helping ian and selling some of the fwd bits that are no longer needed. i ordered some 1"5/8 mandrel bends from ian so i can build my new cossie style exhaust manifold. weve decided to up a size in pipe as the headers are going to be alot shorter than the over the gearbox type. i had a rough idea of what iam going to build so i decided to make a mock manifold out off etecrial wire so i could form the bends . all the cable is the same length to help make it equal length
this is a mock up














heres some of the components











heres the start of the manifold, only spent about an hour tonite so not to bad hope to build a collector at the weekend and get it all tacked together ready for abit of tig , but we will see how we go













heres some pics of the engine with the raceline fully baffled sump which is soon going to be up for sale. its fully gated and has been modified to fit the fiesta zetec engine mount , its also got jic turbo oil return and oil breather return fittings and this has been fully powder coated so keep an eye out in the for non rs for sale section. this is brand new and has never been used even on the dyno . iam selling this to buy a dry sump to gain clearance for the cossie drive shafts and diff.
cheers paul

rst-g

fook me paul that's naughty

zetaboostboy522bhp

which bit mate? that sumps soon to be gone , do you think the cable will hold the t61! ha ha

JonnyBravo

Cool progress, certainly going to be a cool car.

If you don't mind me asking what grade stainless do you use for your manifolds usually ?

zetaboostboy522bhp

[quote=JonnyBravo;4022203]Cool progress, certainly going to be a cool car.

If you don't mind me asking what grade stainless do you use for your manifolds usually ?[/quote


i always use 304 mate as i cant justify the cost of anything else especially when my last one held together so well. to be honest mate there is alot of shit 304 so just check it with a magnet as if its good grade it wont stick.
cheers paul

34CHASSIS

[QUOTE=zetaboostboy522bhp;4022303]hi were do you get the bends from
thanks

Glenn_

iTrader: (1)

Wow yourt a clever man.

fezzajsy

iTrader: (9)

looking good

Matty B898

This is an sweet project.

Love the weldind done on the chassis and the custom mani!!!

rst-g

think your gonna need a turbo hanger on that manifold mate LOL

Zzz...Zzz

Looking really good! Love this fiesta shell with the wide arches!! Good luck finishing the project!!

zetaboostboy522bhp

[quote=34CHASSIS;4022348]i get them off ian howell as he get me a little discount but i have to wait for them , the best place would be ojz engineering mate they have alot of bends on the shelf and are very reasonable
hope this helps mate

zetaboostboy522bhp

i wouldnt go that far mate!

zetaboostboy522bhp

cheers mate and remember ive got my Ł50 waiting!

zetaboostboy522bhp

well had a couple of hours on the exhaust manifold today and not done to bad , i decided to make 2 twin 2-1 straight exhaust collectors for when they meet the turbo flange.that was a job in its self when youve only got a chopsaw and some files but it actually went without any probs. still got to finish it but not that far off, only got to tack one final pipe then make a 2-1 external wastegate pipe and thats it , well still got to buy a t61 twin flange and new tail wastegate flange then its off to my mate for tig welding.
heres some pics

fiesta_xr2i

NICE

rst-g

that looks the dogs! Wish I had the space at home to have all that gear LOL

Mark V8

iTrader: (2)

Nice job on the manifold

Are they 1 5/8 inch stainless mandrel bends ?



It's a difficult size to get hold of usually, can I be cheeky and ask what they cost per bend and where you bought them ?

cheers

Mark

zetaboostboy522bhp

i think ians got a mate who works at ojz engineering so he give me the little discount he gets but he does them when hes ready so it can take sometime to get hold of them but they have a big selection of off the shelf bends anyway with smaller legs around about 15cm each side
you would need to speak to them to get custom bends but the price for the u bends to me where Ł20 each because of the 50cm legs on each end, and yes it is 1"5/8 pipe cause he fucked up 6 lenghts of pipe doin the u bends, hope this helps and cheers for the comments.
p.s nice machining work do you do work on the side mate?

zetaboostboy522bhp

welcome to my second home(and sometimes my first)its brill doors fully locked and away i go mate the only time the missus is allowed in is when shes got a cuppa or stella!

rst in breaking

iTrader: (2)

great work paul, another lovelly manifold

zetaboostboy522bhp

cheers mate , is yours nearly there yet, ive heard that youve got a straight cut gearbox , very cool

Mark V8

iTrader: (2)

Thanks for the info
I have done work on the side in the past but I've just quit my job after over 24 years (real tears)
A 4 day week does not pay the mortgage and I've got the chance to work for the NHS doing one off stuff for a medical physics department. Not much chance to do stuff on the side but it will pay the bills.

Mark

zetaboostboy522bhp

shame that mate your machining work is excellent, but as long as you are alrite and you can pay your bills thats all that matters.
let us know if you need anymore info and good luck with your project
paul

patalrob

Thats a gorgeous looking manifold One heck of a turbo there too!

Maki

please tell us more about that turbo... looks massive

zetaboostboy522bhp

turbonetics t61 rollerbearing turbo, and yes it is massive and its fuckin heavy to mate iam defo gonna need a turbo hanger when running on that new manifold , brilliant turbo just look at the compressor map , we are no where near the limit yet and we are running a medium sized exhaust housing , maybe bigger next time ?
hope this helps
cheers paul

andy escos

iTrader: (1)

that turbo is massive where did you get it m8

zetaboostboy522bhp

this was ians first turbo that he brought for his duratec turbo but then decided that it wasnt big enough for the power he wanted (800bhp) so i think he went for a t72, he had a unused turbo and he wanted rid of it so i give him Ł450 for it after we talked about what power we wanted from my engine , my engine was the development one that ran the t61 first on the dyno to see how it performed , that was over 2 years ago(fuck in hell where does time go) then paul johnson , dan arrowsmith are now using them.
cheers paul

Twellsie

iTrader: (1)

looking good mate, but are you not supposed to have unequal headers on a turbo application?

zetaboostboy522bhp

no mate whos told you that? exhaust gas speed is all important in spooling the turbo up so equal lenght is the way to go as all the headers are pulsing at the same rate producing equal flow
cheers paul

Maki

What A/R would that be?

Neil@FastFord

Getting there, keep it up pal

craigybaby

fair play matey this will be an awesome car when its finished looking forward to seeing the end result and some video clips lol

zetaboostboy522bhp

cheers mate manifold will be done soon , just ordered 4 egt probes from america , a 12mm stainless steel t4 flange and a stainless steel oxygen boss and bung, oh and 44mm tial inlet and outlet flange also from america
so it should be done when the bits turn up

rst in breaking

iTrader: (2)

well i have had the car sent away to have some work done, stainless boost pipe to try and work around the manifold, new downpipe, rover inlet port matched and cossie throttle body flange etc fitted, rose jointed turbo hanger, intercooler chopped about. then when it comes back from there (hopefully late nex weekend) i have to remove the engine to fit new box, then complete all other jobs to it and hop chip cn squeeze me in for mapping as it would be couple of days or so before central day lol

zetaboostboy522bhp

nice one mate , theres no feeling like when your nearly there and all that hard work youve done is finally worth it , hope to see you at central day and hear that box whining!

jikay

Ahh this project is crazy mate!

Saw your shell up at Jim's the other day. Looks amazing mate. You'll have to let me have a look when it's all done.

zetaboostboy522bhp

cheers mate hopefully jims about to start work onit again if hes finished the spaceframed mini , so has he as i have not yet spoken to him?
and as for looking at it no probs mate your welcome to meet up at jim if you want
paul

melspec1

VERY intresting...