Grahams81-Leon 4wd, Big Turbo - Back in the saddle :-)

[Willie]

Bad news Graham.
If it was me and I'd gone this far I'd continue with this manifold and have it completed at some point.
You will have wasted a lot of time, effort and money if you don't finish it.
Thus will allow you to have a back up and Allie testing to see for sure what the differences are.

 

[seatcupramad23]

Indeed I would continue with current manifold and see how it runs if your then nOt happy start agAin with 1.25 it would make good research for future projects the comparison between the two

 

[grahams81]

I would do lads but i dismantled it all on thursday before i came away, i've ordered all the bits for the 1.25" build now so happy days

 

[Scott-o]

You do right Graham, get it all done right first time round, you'll get there soon enough!

Should have left the other one in one bit though, painted it up and made a table or a bog roll holder out of it haha

 

[james.l]

any updates graham?

 

[grahams81]

You do right Graham, get it all done right first time round, you'll get there soon enough!

Should have left the other one in one bit though, painted it up and made a table or a bog roll holder out of it haha

coffee table like top gear one.....Hhmmm not sure the missus will got for that

any updates graham?

Nah mate no update really. I'm back from Ireland now and hopefully off till 9th Jan

So i should get plenty done in the next couple of weeks.
Unfortunately im loaded with cold... Hopefully it won't develop into manflu, the wife wouldn't let me in the garage today but she knowns best..... Apparentley its for my own good but

 

[james.l]

coffee table like top gear one.....Hhmmm not sure the missus will got for that




Nah mate no update really. I'm back from Ireland now and hopefully off till 9th Jan

So i should get plenty done in the next couple of weeks.
Unfortunately im loaded with cold... Hopefully it won't develop into manflu, the wife wouldn't let me in the garage today but she knowns best..... Apparentley its for my own good but

Wifes / girlfriends always know best

 

[gregy_reynolds]

that turbo is the ****ing damage son!!!!!!

 

[grahams81]

1.25" Manifold Build Underway..

Wifes / girlfriends always know best

What ever you do, don't say that when they are in ear-shot.....we'll never live it down

that turbo is the ****ing damage son!!!!!!

Er.. Cheers

Righteeho, so im starting to feel a bit better now, been hitting the Lemsip's & Cold & Flu tablets pretty hard

So Yesterday i went into the garage and cleared away all the 1.5" stuff away and started getting on with the new 1.25" Collector.

I wanted to keep the collector much simpler than the first one i made, using no bends and just straight pipes.

So i used the smallest angle i could make with my chop saw, after seeing it i wasn't too impressed even if i cut the pipes off short it would still be a bit lame -

So this afternoon i started by pulling all the tack welds off the collector so i could start again and try and get a narrower angle on the collector.

So i modified the adjustable angle guide on the chop saw so i could get a nice narrow angle on there, i drilled some extra holes in the angle to get the angle i wanted-

Once happy with the angle i used a G-Clamp on the pipe to keep it secure to the angle -

So i positioned the pipe in line with the front of the angle (so i could repeat the dimension for the other 3 pipes)
I also set the position of the angle in relation to the cutting wheel so the starting point of the cut was roughly in the middle of the pipe.

Piccy of it cut -

So here's a pic of it dressed up, you get a hell of a burr of the chop saw, takes quite a bit of filing up to get shot of it -

So cut the other 3 bits and dressed them up. Then nipped two of them in the vice and tack welded them together -

Break For pics.............

 

[grahams81]

Continued.....

So next up is working out the place to cut the end the new collector so the end size matches up with the hole size of the flange.
What i do is to measure the widest part of the hole in the flange then add on the dimensions of the wall thinkness of the pipe (in this case approx 6mm + Flange dimension) -

So i then tighten the screw on the verniers and pull them down the smallest end of the newly tacked up collector and mark the length where the verniers just touch.
That is then cut in the chop saw (i cut it at a slight angle, so the two pairs angle slightly away from each other)

Pic of it inline with the verniers, after it's been cut to length -

Quick shot of it inside the collector -

So just positioned on the flange to check fitment -

Before i tacked them up on the flange i cut them to length, i chopped the pipes down in line with each other, straight across - rather than at 90 degrees to each pipe. I did it like that to keep the manifold build neat.

Here's a pic of them tacked to the flange -

Really happy with the new collector, it's really nice and neat. The 1.25" pipe is a perfect fit for the T4 Flange, and the angle is nice and narrow so flow will be good.

Shot of the inside of the flange -

So the wife is back at work tomorrow so i will have plenty of time in the garage to play

I will update again tomorrow when i've got the rest of the manifold made.... wishfull thinking me thinks.

Cheers for any comments lads,

Graham.

 

[sambryant]

sweet. very impressive work

 

[CupraElliott]

Good work Graham.

Looks like you have mastered the collector, practicing on plastic piping is worthwhile too, get your angles right etc.

 

[grahams81]

sweet. very impressive work

Cheers

Good work Graham.

Looks like you have mastered the collector, practicing on plastic piping is worthwhile too, get your angles right etc.

Cheers mate, no need for the plactic tho got plenty of practice in making the manifold in the wrong size

It's amazing how much easier it is working with the 1.25" pipes and bends. It seems loads smaller not just 1/4 of an inch. I will take some comparison pics tomorrow

 

[james.l]

Any updates Graham? Been 3 days and nothing which is unlike you?

 

[grahams81]

Soz James been busy Christmas shopping and sitting around playing COD...

Been busy today though....

So started remaking the manifold again... here's a quick shot of the differences in pipe sizes between the 1.5" and 1.25" -

So here's some pictures during the build today, the angles are not 100% as i just wanted to get it tacked up and check clearances and lengths etc.
The length of the runners is spot on within 1/2" of each other - really happy about that

So started with the middle cylinders -

Before i went any further i fitted it to the engine, then bolted the turbo on to check for downpipe clearance -

Break for Piccy's

 

[grahams81]

Continued............

Then did cylinder 3 -

So hopefully tomorrow get the forth cylinder done and then start fine tuning it all and getting all the pipe ends nice and square.

Ta-tar..

 

[james.l]

Pure filth! Excellent work!

I've been smashing a bit of cod too

 

[ibizacupra]

nice watching this evolve

 

[Miller 20vt]

love seeing updates on this...such a great home build!! looking forward to the nest update!!

 

[joehirth]

Graham, I don't know if you'll regret not being able to remove the cam cover I would find it most annoying! I'm not sure if it's a lot more fuss to just extend it an inch or so towards the passengers side??

Are you a PS3 or Xbox man though?! gotta love COD