Mk6 JWRC fiesta cosworth
02-12-2013, 09:59 PM
#3121
PassionFord Post Whore!!
Join Date: Nov 2006
Location: .
Posts: 3,538
Likes: 0
Received 0 Likes
on
0 Posts
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?
04-12-2013, 06:45 AM
#3123
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
12-12-2013, 10:27 PM
#3124
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
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
Nice tight fit
Got them tacked in place,
Next up was setting up the purge gas, so tapped up and purged with about 5lpm of argon flow
And the end result is one very happy me
Tonights handywork
The downpipe back in place for a double check
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
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
Nice tight fit
Got them tacked in place,
Next up was setting up the purge gas, so tapped up and purged with about 5lpm of argon flow
And the end result is one very happy me
Tonights handywork
The downpipe back in place for a double check
That is all for now
Thanks
Marc
13-12-2013, 02:42 PM
#3128
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
13-12-2013, 04:22 PM
#3129
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
15-12-2013, 02:57 PM
#3135
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
18-12-2013, 07:26 AM
#3143
Advanced PassionFord User
Are you in danger of turning into a welding bufty? You'll have more masks and bits for welding than car parts soon
18-12-2013, 11:31 AM
#3144
BANNED
BANNED
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
19-12-2013, 11:56 AM
#3145
Practice practice practice, did you go for a tig set in the end?
19-12-2013, 04:03 PM
#3147
PassionFord Post Troll
iTrader: (2)
Join Date: May 2003
Location: In my garage, coventry
Posts: 3,065
Likes: 0
Received 2 Likes
on
2 Posts
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.
20-12-2013, 03:57 PM
#3148
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
Last edited by M K; 20-12-2013 at 04:00 PM.
22-12-2013, 06:50 PM
#3150
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
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
Beforehand Ready to weld
Next v-band tacked in place
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
A 90 bend that needed extending on one leg tacked and ready to be purge welded
All done
Next couple of bends tacked into place
And how I left it for today
Flexi in position
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
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
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
Beforehand Ready to weld
Next v-band tacked in place
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
A 90 bend that needed extending on one leg tacked and ready to be purge welded
All done
Next couple of bends tacked into place
And how I left it for today
Flexi in position
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
Will properly purge weld that lot tomorrow
Thanks
Marc
Last edited by M K; 22-12-2013 at 06:54 PM.
23-12-2013, 03:25 PM
#3155
Wahay!! I've lost my Virginity!!
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
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
Beforehand Ready to weld
Next v-band tacked in place
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
A 90 bend that needed extending on one leg tacked and ready to be purge welded
All done
Next couple of bends tacked into place
And how I left it for today
Flexi in position
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
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
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
Beforehand Ready to weld
Next v-band tacked in place
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
A 90 bend that needed extending on one leg tacked and ready to be purge welded
All done
Next couple of bends tacked into place
And how I left it for today
Flexi in position
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
Will properly purge weld that lot tomorrow
Thanks
Marc
Gerry
23-12-2013, 09:57 PM
#3156
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
rest all welded up
cut out gearbox mount
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
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
rest all welded up
cut out gearbox mount
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
Thanks
Marc
Last edited by M K; 23-12-2013 at 10:00 PM.
