CA18DET Topmount build and S14 T28 **ADSL**
Posted: Tue Oct 01, 2013 9:46 pm
Well after selling my T25 to a friend in need i felt it was time i finally started getting my T28 together and on as planned. I was determined to go topmount manifold with external wastegate as i wanted something different compared to just bolting on a T28 to standard setup. After buying a home made manifold off gumtree i was never really pleased with it and delaid the project even further hoping to find something better, nothing came up so i started some research and thought if i want it done right i must just do it myself, so here il post a whole bunch of pics of what ive been up to, forgive me for sparing details as i dont really have the energy to type out how i did it all, but im sure the pictures will be quite insightfull. Enjoy:
How things look after stripping:
the ABS removed and T'd off:
Power Steering bottle relocated:
Turbo Make-over:
Must still clean up the exhaust housing a bit and spray it hi-heat black, itl burn off after some time but even the burnt layer protects and looks better than the rust from what ive seen with previous turbos ive sprayed, heres how i sprayed the external wastegate also with the hi-heat:
Heres how i made my merge collector, using all 40mm inside diameter steel steam pipe, first i made a mockup with 40mm PVC to check all my intersect angles and everything came together good so i could continue with the steel pipes.
Once the T2 flange was spot welded in place i bolted it tightly to a spare cracked housing to ensure that the steel flange did not warp during welding, and it worked like a charm, no need to skim the flange
Heres how i designed the flange templates to send away for laser cutting:
Once the merge collector was finished i could then bolt it to the complete turbo and position the turbo where i wanted it to be in the engine bay, once positioned i welded a rod from the merge collector to the cylinder head turbo manifold flange and from that placement i could then create my complete manifold on the bench:
After all of cylinders 2,3,4 was in place i then had to remove my rod to make space to make my cylinder 1 bend:
i then moved the rod to the other side to ensure the merge collector stays in place as to weld the manifold properly i will removed each cylinders pipe and weld it all together one by one and then weld it to the manifold again that way i wont struggle to weld inbetween too tight spots where piping passes right next to each other
i also designed the manifold in such a way that it keeps the firing order in sequence when it enters and circulates in the merge collector, well i read it online from alot of pro tuners. Im no expert and this is the first manifold ive ever made, but im very happy with the result and im sure it will perform well and it will definately not crack anytime soon like the cheap stainles manifolds.
Theres stil alot more work to be done such as downpipe, FMIC and boost pipes, a few adapters, oil feed lines and water feed, manifold must be welded finished and then coated some how, must redo power steering lines and make up some heat shields aswell as hole saw cut a hole in the merge collector and weld my external wastegate piping and flange in place, lots of work, so will keep updating. Hope you guys enjoyed the pics and comments are welcome.
How things look after stripping:
the ABS removed and T'd off:
Power Steering bottle relocated:
Turbo Make-over:
Must still clean up the exhaust housing a bit and spray it hi-heat black, itl burn off after some time but even the burnt layer protects and looks better than the rust from what ive seen with previous turbos ive sprayed, heres how i sprayed the external wastegate also with the hi-heat:
Heres how i made my merge collector, using all 40mm inside diameter steel steam pipe, first i made a mockup with 40mm PVC to check all my intersect angles and everything came together good so i could continue with the steel pipes.
Once the T2 flange was spot welded in place i bolted it tightly to a spare cracked housing to ensure that the steel flange did not warp during welding, and it worked like a charm, no need to skim the flange
Heres how i designed the flange templates to send away for laser cutting:
Once the merge collector was finished i could then bolt it to the complete turbo and position the turbo where i wanted it to be in the engine bay, once positioned i welded a rod from the merge collector to the cylinder head turbo manifold flange and from that placement i could then create my complete manifold on the bench:
After all of cylinders 2,3,4 was in place i then had to remove my rod to make space to make my cylinder 1 bend:
i then moved the rod to the other side to ensure the merge collector stays in place as to weld the manifold properly i will removed each cylinders pipe and weld it all together one by one and then weld it to the manifold again that way i wont struggle to weld inbetween too tight spots where piping passes right next to each other
i also designed the manifold in such a way that it keeps the firing order in sequence when it enters and circulates in the merge collector, well i read it online from alot of pro tuners. Im no expert and this is the first manifold ive ever made, but im very happy with the result and im sure it will perform well and it will definately not crack anytime soon like the cheap stainles manifolds.
Theres stil alot more work to be done such as downpipe, FMIC and boost pipes, a few adapters, oil feed lines and water feed, manifold must be welded finished and then coated some how, must redo power steering lines and make up some heat shields aswell as hole saw cut a hole in the merge collector and weld my external wastegate piping and flange in place, lots of work, so will keep updating. Hope you guys enjoyed the pics and comments are welcome.