Mk6 JWRC fiesta cosworth
#3121
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work looks awesome as ever and I'll hold my handds up in saying I've never welded so not an expert - but is winding the cable round your arm a good idea? what happens if you want to drop it in a hurry for some reason?
#3123
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Big chez - it's fine wrapped round my arm, there's absolutely no chance of me needing to drop it quickly and even if I did, the super flex cable is so soft and flexible if I dropped my arm down it would just fall off,
Well worth the money for any tig welders out there wanting a new torch
Well worth the money for any tig welders out there wanting a new torch
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#3124
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Not had much time of late but got a few hours in tonight and done a bit more to the downpipe section of the exhaust system i am making,
done a few hours practice before doing these bits as my stainless welding was coming out very grey before due to welding too hot so practice practice practice and really happy with tonight's work,
1st off is the start of the v-band flange for the external wastegate, just welded into onto a short straight piece of tube to start then i will cut down as i work out exactly where things are going as i am piping this back into the downpipe,
Did not purge this as it did not need it, very happy with it
![Name: IMG_6039_zps7c79e5da.jpg
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Size: 68.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72959d1501461557-mk6-jwrc-fiesta-cosworth-img_6039_zps7c79e5da.jpg)
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Size: 68.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72961d1501461557-mk6-jwrc-fiesta-cosworth-img_6046_zps3f42a3a6.jpg)
More on that in the next week or so,
Next up i managed to borrow an old knackered lambda sensor so i could check clearance and get the 2 lambda bosses welded into the downpipe, the reason for having 2 is that if the car is mapped etc and they wish to fit there own lambda sensor which is often the case then mine does not have to be removed and fooked about with,
So marked up and cut the holes for them
![Name: IMG_6032_zps86fdcc9a.jpg
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Size: 71.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72962d1501461557-mk6-jwrc-fiesta-cosworth-img_6032_zps86fdcc9a.jpg)
Nice tight fit
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/IMG_6033_zpsef3a5fd9.jpg)
![Name: IMG_6034_zps27f289e7.jpg
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Got them tacked in place,
![Name: IMG_6035_zpsde4a0b41.jpg
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Next up was setting up the purge gas, so tapped up and purged with about 5lpm of argon flow
![Name: IMG_6037_zps10fd1d83.jpg
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Size: 78.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72965d1501461557-mk6-jwrc-fiesta-cosworth-img_6037_zps10fd1d83.jpg)
And the end result is one very happy me![](http://www.escortrscosworth.com/forum/images/smilies/content.gif)
![](http://www.escortrscosworth.com/forum/images/smilies/content.gif)
![](http://www.escortrscosworth.com/forum/images/smilies/content.gif)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/IMG_6045_zps12ce0162.jpg)
![Name: IMG_6043_zps21f38f43.jpg
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Tonights handywork
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The downpipe back in place for a double check
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That is all for now
Thanks
Marc
done a few hours practice before doing these bits as my stainless welding was coming out very grey before due to welding too hot so practice practice practice and really happy with tonight's work,
1st off is the start of the v-band flange for the external wastegate, just welded into onto a short straight piece of tube to start then i will cut down as i work out exactly where things are going as i am piping this back into the downpipe,
Did not purge this as it did not need it, very happy with it
![Name: IMG_6039_zps7c79e5da.jpg
Views: 226
Size: 68.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72959d1501461557-mk6-jwrc-fiesta-cosworth-img_6039_zps7c79e5da.jpg)
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More on that in the next week or so,
Next up i managed to borrow an old knackered lambda sensor so i could check clearance and get the 2 lambda bosses welded into the downpipe, the reason for having 2 is that if the car is mapped etc and they wish to fit there own lambda sensor which is often the case then mine does not have to be removed and fooked about with,
So marked up and cut the holes for them
![Name: IMG_6032_zps86fdcc9a.jpg
Views: 239
Size: 71.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72962d1501461557-mk6-jwrc-fiesta-cosworth-img_6032_zps86fdcc9a.jpg)
Nice tight fit
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/IMG_6033_zpsef3a5fd9.jpg)
![Name: IMG_6034_zps27f289e7.jpg
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Got them tacked in place,
![Name: IMG_6035_zpsde4a0b41.jpg
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Size: 62.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72964d1501461557-mk6-jwrc-fiesta-cosworth-img_6035_zpsde4a0b41.jpg)
Next up was setting up the purge gas, so tapped up and purged with about 5lpm of argon flow
![Name: IMG_6037_zps10fd1d83.jpg
Views: 227
Size: 78.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72965d1501461557-mk6-jwrc-fiesta-cosworth-img_6037_zps10fd1d83.jpg)
And the end result is one very happy me
![](http://www.escortrscosworth.com/forum/images/smilies/content.gif)
![](http://www.escortrscosworth.com/forum/images/smilies/content.gif)
![](http://www.escortrscosworth.com/forum/images/smilies/content.gif)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/IMG_6045_zps12ce0162.jpg)
![Name: IMG_6043_zps21f38f43.jpg
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Tonights handywork
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The downpipe back in place for a double check
![Name: IMG_6049_zpsb3529d9f.jpg
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That is all for now
Thanks
Marc
![](http://www.escortrscosworth.com/forum/images/smilies/Thumbs.gif)
#3128
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Cheers guys, yeah well happy with the results
Luke89 - that was welded with 32amps, 2.4 gold tungsten pointed tip, 1.6mm 308l filler rod, no pulse, ck9 torch,
I'm the same, it's taken me longer to get the hang on stainless than it did ally but Ive still a shit load to learn about both before I get up to standard
Luke89 - that was welded with 32amps, 2.4 gold tungsten pointed tip, 1.6mm 308l filler rod, no pulse, ck9 torch,
I'm the same, it's taken me longer to get the hang on stainless than it did ally but Ive still a shit load to learn about both before I get up to standard
#3129
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Cheers guys, yeah well happy with the results
Luke89 - that was welded with 32amps, 2.4 gold tungsten pointed tip, 1.6mm 308l filler rod, no pulse, ck9 torch,
I'm the same, it's taken me longer to get the hang on stainless than it did ally but Ive still a shit load to learn about both before I get up to standard
Luke89 - that was welded with 32amps, 2.4 gold tungsten pointed tip, 1.6mm 308l filler rod, no pulse, ck9 torch,
I'm the same, it's taken me longer to get the hang on stainless than it did ally but Ive still a shit load to learn about both before I get up to standard
try 1.6 tungsten with 1.6 rod
mark
#3135
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Cheers guys
As for the lambda, I'm sure it will be fine there, also the full blown ntk wrc/Motorsport lambda's are a bit more robust than the standard Bosch items, well I hope so when the cost about Ł400 lol
That one in the photo is just an old dead Bosch use for mock up
As for the lambda, I'm sure it will be fine there, also the full blown ntk wrc/Motorsport lambda's are a bit more robust than the standard Bosch items, well I hope so when the cost about Ł400 lol
That one in the photo is just an old dead Bosch use for mock up
#3143
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Are you in danger of turning into a welding bufty? You'll have more masks and bits for welding than car parts soon
#3144
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Absoloutly stunning!!!
Welding is totally different from a few pics ago. I would like to say your starting to get the hang of it but I think you past that point a few pages back lol
Keep up the good work.
p.s. CANNNTTTT!! x
Welding is totally different from a few pics ago. I would like to say your starting to get the hang of it but I think you past that point a few pages back lol
Keep up the good work.
p.s. CANNNTTTT!! x
#3145
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Practice practice practice, did you go for a tig set in the end?
#3147
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Awesome coming along great
I also have the clumsy rtec tig torch
Can you pm me the part number for the ck torch and the Pyrex gas
Lens please,
You have inspired me to get the dust off my tig lol
I also have the clumsy rtec tig torch
Can you pm me the part number for the ck torch and the Pyrex gas
Lens please,
You have inspired me to get the dust off my tig lol
Last edited by Alg1k; 20-12-2013 at 03:11 PM.
#3148
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http://www.rapidwelding.com/dynamic/...=CK-CK912RSFFX
This is the adapter needed for the r-tech tig i think but double check before buying or call them as the bloke new exactly what one i needed for the r-tech
http://www.rapidwelding.com/dynamic/...SL235-BSP&zl=2
Also ordered this large diameter gas saver pyrex lens but havent tried it yet as it is a xmas present but supposed to give awesome gas coverage and allow up to 2" stick out for real awkward areas
http://www.rapidwelding.com/dynamic/...c=CK-D2GSXXXLD
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Last edited by M K; 20-12-2013 at 04:00 PM.
#3150
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Had another go at the exhaust today
Just to show you quickly what I done the day before,
A 3" purge bung for purge welding the exhaust, holds better than just lashing loads of tape around the end and allows a proper seal
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I cut off the v-band at the top if the housing, it was slightly warped where I had welded with too much heat and I wasn't happy with it so thought better to do it now then find it blows when running later,
New v-band welded on
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Beforehand Ready to weld
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Next v-band tacked in place
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I have found even tacking will pull the v-band out of shape so tack with both halfs tightly clamped up,
Adding a v-band here leaves me with a very short downpipe so if I ever wanted to change the downpipe it's only a small piece,
Showing position just next to diff
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A 90 bend that needed extending on one leg tacked and ready to be purge welded
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All done
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Next couple of bends tacked into place
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/F1672670-68D8-4550-96C5-F1C5BBB2DA4A_zps0amwclio.jpg)
And how I left it for today
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Flexi in position
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The exhaust will pass in between the gearbox brace and gearbox but as it's a tight fit I will cut out and flatten of part of the gearbox mount to allow more room as I don't want it knocking
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/08446C98-1297-430A-ADB9-7685B3C51E57_zpsrnc3hzn6.jpg)
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Will properly purge weld that lot tomorrow
Thanks
Marc
Just to show you quickly what I done the day before,
A 3" purge bung for purge welding the exhaust, holds better than just lashing loads of tape around the end and allows a proper seal
![Name: DC47B109-434F-4F0D-97D4-4E23AECDF5B3_zpsoj9pwjb1.jpg
Views: 220
Size: 107.9 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72234d1501459595-mk6-jwrc-fiesta-cosworth-dc47b109-434f-4f0d-97d4-4e23aecdf5b3_zpsoj9pwjb1.jpg)
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![Name: ED1BB675-B7D2-4185-A75E-81E4C1398D23_zpsr1oftiiu.jpg
Views: 205
Size: 125.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72237d1501459595-mk6-jwrc-fiesta-cosworth-ed1bb675-b7d2-4185-a75e-81e4c1398d23_zpsr1oftiiu.jpg)
I cut off the v-band at the top if the housing, it was slightly warped where I had welded with too much heat and I wasn't happy with it so thought better to do it now then find it blows when running later,
New v-band welded on
![Name: 4E81E02C-77E5-4CBF-82CF-24911529B7C1_zpsjr8agzo2.jpg
Views: 221
Size: 105.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72238d1501459595-mk6-jwrc-fiesta-cosworth-4e81e02c-77e5-4cbf-82cf-24911529b7c1_zpsjr8agzo2.jpg)
![Name: D7DDC2B9-36D5-48E5-ADF8-75A493E4CD4B_zpsvz6qt8ec.jpg
Views: 207
Size: 147.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72239d1501459595-mk6-jwrc-fiesta-cosworth-d7ddc2b9-36d5-48e5-adf8-75a493e4cd4b_zpsvz6qt8ec.jpg)
Beforehand Ready to weld
![Name: 7DCA3945-14D9-499D-A047-01ECE474173D_zpsy8ht6m2u.jpg
Views: 222
Size: 118.2 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72240d1501459595-mk6-jwrc-fiesta-cosworth-7dca3945-14d9-499d-a047-01ece474173d_zpsy8ht6m2u.jpg)
Next v-band tacked in place
![Name: 57732A00-5D71-4767-9403-A97213C05138_zpsfqdvs72u.jpg
Views: 205
Size: 70.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72241d1501459595-mk6-jwrc-fiesta-cosworth-57732a00-5d71-4767-9403-a97213c05138_zpsfqdvs72u.jpg)
I have found even tacking will pull the v-band out of shape so tack with both halfs tightly clamped up,
Adding a v-band here leaves me with a very short downpipe so if I ever wanted to change the downpipe it's only a small piece,
Showing position just next to diff
![Name: 6B38874B-D6F3-47D7-AD35-3BAD6A2040A4_zpsxnmk9kwc.jpg
Views: 215
Size: 115.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72242d1501459595-mk6-jwrc-fiesta-cosworth-6b38874b-d6f3-47d7-ad35-3bad6a2040a4_zpsxnmk9kwc.jpg)
A 90 bend that needed extending on one leg tacked and ready to be purge welded
![Name: FC9CA41F-D377-4667-98EE-3E0318B91E92_zpsqadkalyf.jpg
Views: 216
Size: 86.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72243d1501459595-mk6-jwrc-fiesta-cosworth-fc9ca41f-d377-4667-98ee-3e0318b91e92_zpsqadkalyf.jpg)
All done
![Name: E7B4C7F6-7CEC-4F2E-BE0F-D3EA5502CF89_zps1hjpv9vq.jpg
Views: 198
Size: 91.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72244d1501459595-mk6-jwrc-fiesta-cosworth-e7b4c7f6-7cec-4f2e-be0f-d3ea5502cf89_zps1hjpv9vq.jpg)
Next couple of bends tacked into place
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/F1672670-68D8-4550-96C5-F1C5BBB2DA4A_zps0amwclio.jpg)
And how I left it for today
![Name: 2D1821C2-EC06-4757-84CD-D7AAE7B3A2E2_zpsncbazss7.jpg
Views: 218
Size: 81.4 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72245d1501459595-mk6-jwrc-fiesta-cosworth-2d1821c2-ec06-4757-84cd-d7aae7b3a2e2_zpsncbazss7.jpg)
![Name: 429B59C2-9CE6-4658-80E6-5C2D30440E28_zpsrmv61tyi.jpg
Views: 206
Size: 108.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72246d1501459595-mk6-jwrc-fiesta-cosworth-429b59c2-9ce6-4658-80e6-5c2d30440e28_zpsrmv61tyi.jpg)
Flexi in position
![Name: 063ECABD-19A8-4851-8C35-D1320C7349F7_zpstpkswwuf.jpg
Views: 222
Size: 112.6 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72247d1501459595-mk6-jwrc-fiesta-cosworth-063ecabd-19a8-4851-8c35-d1320c7349f7_zpstpkswwuf.jpg)
The exhaust will pass in between the gearbox brace and gearbox but as it's a tight fit I will cut out and flatten of part of the gearbox mount to allow more room as I don't want it knocking
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/08446C98-1297-430A-ADB9-7685B3C51E57_zpsrnc3hzn6.jpg)
![Name: CE31A1C8-C7BE-46B6-8098-7DAA364D9685_zps4v9drefn.jpg
Views: 218
Size: 100.9 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72248d1501459595-mk6-jwrc-fiesta-cosworth-ce31a1c8-c7be-46b6-8098-7daa364d9685_zps4v9drefn.jpg)
![Name: 690CB481-B68C-45D4-8D10-5D820C5508B0_zpsjo8vechu.jpg
Views: 212
Size: 98.9 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72249d1501459595-mk6-jwrc-fiesta-cosworth-690cb481-b68c-45d4-8d10-5d820c5508b0_zpsjo8vechu.jpg)
Will properly purge weld that lot tomorrow
Thanks
Marc
![Top](https://passionford.com/forum/images/smilies/smile011.gif)
Last edited by M K; 22-12-2013 at 06:54 PM.
#3155
Wahay!! I've lost my Virginity!!
![Default](https://passionford.com/forum/images/icons/icon1.gif)
Had another go at the exhaust today
Just to show you quickly what I done the day before,
A 3" purge bung for purge welding the exhaust, holds better than just lashing loads of tape around the end and allows a proper seal
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/DC47B109-434F-4F0D-97D4-4E23AECDF5B3_zpsoj9pwjb1.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/9A03F320-06D2-4A5C-B84B-5819FF312992_zpsam2cvoc7.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/AC483777-F97C-4A96-9424-DA0675D42BAB_zpsqbp68trb.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/ED1BB675-B7D2-4185-A75E-81E4C1398D23_zpsr1oftiiu.jpg)
I cut off the v-band at the top if the housing, it was slightly warped where I had welded with too much heat and I wasn't happy with it so thought better to do it now then find it blows when running later,
New v-band welded on
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/4E81E02C-77E5-4CBF-82CF-24911529B7C1_zpsjr8agzo2.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/D7DDC2B9-36D5-48E5-ADF8-75A493E4CD4B_zpsvz6qt8ec.jpg)
Beforehand Ready to weld
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/7DCA3945-14D9-499D-A047-01ECE474173D_zpsy8ht6m2u.jpg)
Next v-band tacked in place
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/57732A00-5D71-4767-9403-A97213C05138_zpsfqdvs72u.jpg)
I have found even tacking will pull the v-band out of shape so tack with both halfs tightly clamped up,
Adding a v-band here leaves me with a very short downpipe so if I ever wanted to change the downpipe it's only a small piece,
Showing position just next to diff
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/6B38874B-D6F3-47D7-AD35-3BAD6A2040A4_zpsxnmk9kwc.jpg)
A 90 bend that needed extending on one leg tacked and ready to be purge welded
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/FC9CA41F-D377-4667-98EE-3E0318B91E92_zpsqadkalyf.jpg)
All done
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/E7B4C7F6-7CEC-4F2E-BE0F-D3EA5502CF89_zps1hjpv9vq.jpg)
Next couple of bends tacked into place
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/F1672670-68D8-4550-96C5-F1C5BBB2DA4A_zps0amwclio.jpg)
And how I left it for today
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/2D1821C2-EC06-4757-84CD-D7AAE7B3A2E2_zpsncbazss7.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/429B59C2-9CE6-4658-80E6-5C2D30440E28_zpsrmv61tyi.jpg)
Flexi in position
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/063ECABD-19A8-4851-8C35-D1320C7349F7_zpstpkswwuf.jpg)
The exhaust will pass in between the gearbox brace and gearbox but as it's a tight fit I will cut out and flatten of part of the gearbox mount to allow more room as I don't want it knocking
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/08446C98-1297-430A-ADB9-7685B3C51E57_zpsrnc3hzn6.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/CE31A1C8-C7BE-46B6-8098-7DAA364D9685_zps4v9drefn.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/690CB481-B68C-45D4-8D10-5D820C5508B0_zpsjo8vechu.jpg)
Will properly purge weld that lot tomorrow
Thanks
Marc
![Top](https://passionford.com/forum/images/smilies/smile011.gif)
Just to show you quickly what I done the day before,
A 3" purge bung for purge welding the exhaust, holds better than just lashing loads of tape around the end and allows a proper seal
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/DC47B109-434F-4F0D-97D4-4E23AECDF5B3_zpsoj9pwjb1.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/9A03F320-06D2-4A5C-B84B-5819FF312992_zpsam2cvoc7.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/AC483777-F97C-4A96-9424-DA0675D42BAB_zpsqbp68trb.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/ED1BB675-B7D2-4185-A75E-81E4C1398D23_zpsr1oftiiu.jpg)
I cut off the v-band at the top if the housing, it was slightly warped where I had welded with too much heat and I wasn't happy with it so thought better to do it now then find it blows when running later,
New v-band welded on
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/4E81E02C-77E5-4CBF-82CF-24911529B7C1_zpsjr8agzo2.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/D7DDC2B9-36D5-48E5-ADF8-75A493E4CD4B_zpsvz6qt8ec.jpg)
Beforehand Ready to weld
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/7DCA3945-14D9-499D-A047-01ECE474173D_zpsy8ht6m2u.jpg)
Next v-band tacked in place
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/57732A00-5D71-4767-9403-A97213C05138_zpsfqdvs72u.jpg)
I have found even tacking will pull the v-band out of shape so tack with both halfs tightly clamped up,
Adding a v-band here leaves me with a very short downpipe so if I ever wanted to change the downpipe it's only a small piece,
Showing position just next to diff
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/6B38874B-D6F3-47D7-AD35-3BAD6A2040A4_zpsxnmk9kwc.jpg)
A 90 bend that needed extending on one leg tacked and ready to be purge welded
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/FC9CA41F-D377-4667-98EE-3E0318B91E92_zpsqadkalyf.jpg)
All done
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/E7B4C7F6-7CEC-4F2E-BE0F-D3EA5502CF89_zps1hjpv9vq.jpg)
Next couple of bends tacked into place
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/F1672670-68D8-4550-96C5-F1C5BBB2DA4A_zps0amwclio.jpg)
And how I left it for today
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/2D1821C2-EC06-4757-84CD-D7AAE7B3A2E2_zpsncbazss7.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/429B59C2-9CE6-4658-80E6-5C2D30440E28_zpsrmv61tyi.jpg)
Flexi in position
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/063ECABD-19A8-4851-8C35-D1320C7349F7_zpstpkswwuf.jpg)
The exhaust will pass in between the gearbox brace and gearbox but as it's a tight fit I will cut out and flatten of part of the gearbox mount to allow more room as I don't want it knocking
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/08446C98-1297-430A-ADB9-7685B3C51E57_zpsrnc3hzn6.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/CE31A1C8-C7BE-46B6-8098-7DAA364D9685_zps4v9drefn.jpg)
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/690CB481-B68C-45D4-8D10-5D820C5508B0_zpsjo8vechu.jpg)
Will properly purge weld that lot tomorrow
Thanks
Marc
![Top](https://passionford.com/forum/images/smilies/smile011.gif)
Gerry
#3156
![Default](https://passionford.com/forum/images/icons/icon1.gif)
Hi Gerry,
I just buy the bends in mate or if it's something other than a 45 or 90 then i make it up myself with multiple sections welded,
Done a bit more today but had a real headache with the v-bands today,
The first one i redone yesterday for the turbo rear housing welding mint and was not warped 1 bit so happy days i thought, but today doing the second one it kept warping so i cut it off and re did then cut it off and re did then re did again but still it bloody warped so rather than waste more flanges i gave up and got it as good as i could, i will see if it seals once running and either use a v-band gasket or a laser cut shim or something similar, i welded fast and with low amps, (about 60-70) and i had the v-band clamped to the other half but still it warped slightly so il see how i get on, a gasket or shim is no drama really or even face the flanges on the belt sander,
Anyway, 1 slightly warped v-band but with awesome welds lol
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/983355CD-A426-4476-AED6-040326CAB43E_zpswdw82nza.jpg)
![Name: B2ADDDEA-5286-4827-B7CF-15DA9086126A_zpslmntwytx.jpg
Views: 202
Size: 79.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72157d1501459409-mk6-jwrc-fiesta-cosworth-b2adddea-5286-4827-b7cf-15da9086126a_zpslmntwytx.jpg)
rest all welded up
![Name: 33FB1C5F-3CBE-485C-BF29-484A95BB36CE_zps8clrdfty.jpg
Views: 259
Size: 113.1 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72158d1501459409-mk6-jwrc-fiesta-cosworth-33fb1c5f-3cbe-485c-bf29-484a95bb36ce_zps8clrdfty.jpg)
cut out gearbox mount
![Name: 9AAFECA2-A168-49D7-987F-D4D0BABD9A6B_zpsuivezhub.jpg
Views: 211
Size: 87.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72159d1501459409-mk6-jwrc-fiesta-cosworth-9aafeca2-a168-49d7-987f-d4d0babd9a6b_zpsuivezhub.jpg)
![Name: E9C8F22D-4FFC-4561-8AB9-35E680B40174_zpsxiesgdww.jpg
Views: 230
Size: 68.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72160d1501459409-mk6-jwrc-fiesta-cosworth-e9c8f22d-4ffc-4561-8ab9-35e680b40174_zpsxiesgdww.jpg)
All in place for now, not going to do anymore as need another 45 bend and some bar for hangers and a couple of heavy duty rubbers for mounting
![Name: 6246EF57-2567-4F78-84D0-03F8AD04730F_zpsdhxstyep.jpg
Views: 231
Size: 93.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72161d1501459409-mk6-jwrc-fiesta-cosworth-6246ef57-2567-4f78-84d0-03f8ad04730f_zpsdhxstyep.jpg)
![Name: 9630CF34-FFEE-4C8B-A866-1558E43040E2_zpsskfnu8bi.jpg
Views: 214
Size: 116.0 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72162d1501459409-mk6-jwrc-fiesta-cosworth-9630cf34-ffee-4c8b-a866-1558e43040e2_zpsskfnu8bi.jpg)
![Name: E249158A-BB09-4A99-911D-DD3C7AEEB58A_zpsx1mohcfp.jpg
Views: 231
Size: 89.3 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72163d1501459409-mk6-jwrc-fiesta-cosworth-e249158a-bb09-4a99-911d-dd3c7aeeb58a_zpsx1mohcfp.jpg)
Thanks
Marc
I just buy the bends in mate or if it's something other than a 45 or 90 then i make it up myself with multiple sections welded,
Done a bit more today but had a real headache with the v-bands today,
The first one i redone yesterday for the turbo rear housing welding mint and was not warped 1 bit so happy days i thought, but today doing the second one it kept warping so i cut it off and re did then cut it off and re did then re did again but still it bloody warped so rather than waste more flanges i gave up and got it as good as i could, i will see if it seals once running and either use a v-band gasket or a laser cut shim or something similar, i welded fast and with low amps, (about 60-70) and i had the v-band clamped to the other half but still it warped slightly so il see how i get on, a gasket or shim is no drama really or even face the flanges on the belt sander,
Anyway, 1 slightly warped v-band but with awesome welds lol
![](http://img.photobucket.com/albums/v104/CHICKAROO/MK6%20FIESTA%20JWRC%20COSWORTH%20PROJECT/983355CD-A426-4476-AED6-040326CAB43E_zpswdw82nza.jpg)
![Name: B2ADDDEA-5286-4827-B7CF-15DA9086126A_zpslmntwytx.jpg
Views: 202
Size: 79.8 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72157d1501459409-mk6-jwrc-fiesta-cosworth-b2adddea-5286-4827-b7cf-15da9086126a_zpslmntwytx.jpg)
rest all welded up
![Name: 33FB1C5F-3CBE-485C-BF29-484A95BB36CE_zps8clrdfty.jpg
Views: 259
Size: 113.1 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72158d1501459409-mk6-jwrc-fiesta-cosworth-33fb1c5f-3cbe-485c-bf29-484a95bb36ce_zps8clrdfty.jpg)
cut out gearbox mount
![Name: 9AAFECA2-A168-49D7-987F-D4D0BABD9A6B_zpsuivezhub.jpg
Views: 211
Size: 87.5 KB](https://passionford.com/forum/attachments/restorations-rebuilds-and-projects/72159d1501459409-mk6-jwrc-fiesta-cosworth-9aafeca2-a168-49d7-987f-d4d0babd9a6b_zpsuivezhub.jpg)
![Name: E9C8F22D-4FFC-4561-8AB9-35E680B40174_zpsxiesgdww.jpg
Views: 230
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All in place for now, not going to do anymore as need another 45 bend and some bar for hangers and a couple of heavy duty rubbers for mounting
![Name: 6246EF57-2567-4F78-84D0-03F8AD04730F_zpsdhxstyep.jpg
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![Name: E249158A-BB09-4A99-911D-DD3C7AEEB58A_zpsx1mohcfp.jpg
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Thanks
Marc
Last edited by M K; 23-12-2013 at 10:00 PM.