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Building a TwinScroll Header

If you've never made a header/manifold before you will get way more experience by cutting op pieces of pipe & elbows and figuring it out then by drawing a cad model.
You did sone fabrication before on exhausts iirc, you will figure this one out also ;)
 
Started to fiddle around with my bandsaw to get some decent cuts to fab a collector.. havent found the best way, but i got 2 scrolls welded together yesterday looking not that bad :)

You can't say that and not post pictures!!!

BTW: Your cad model looks good, but the cylinder head flange is upside down for a top-mounted turbo ;-)

As far as positioning, I think where you put it next to the motor looks good, but definitely wait till you can mock-up in the car so you can place it as far back to the strut tower as possible. Otherwise you might have to do some impromtu mods with a hammer to get it in...

But these would also be fun to use
https://www.trick-tools.com/Icengineworks-Exhaust-Header-Modeling-Systems-864

For a kit costing $1,400 you could just buy a 3D-Printer and make a bunch as you go for 20% of the price. :hyper:

https://www.thingiverse.com/thing:1831000 2.000"
https://www.thingiverse.com/thing:2053049 1.750"
https://www.thingiverse.com/thing:1649639 1.625"
https://www.thingiverse.com/thing:2305656 1.500"

And for the downpipe and exhaust
https://www.thingiverse.com/thing:2305581 3.000"
https://www.thingiverse.com/thing:1994896 2.500"
 
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Is this turbo going on your 240 or the 940? -hope for your sake it's the 940!
I fitted a turbo in a 240 & it was a nightmare- your turbo looks bigger than the one I have!
It's best to trial fit it in position in the engine bay. I didn't but took lots of measurements & fabbed it up on an engine on a stand. You tend to miss a lot of obstructions doing it that way - like the water pump/hoses, distrubutor & that pipe that goes from the water pump to the heater. I think there's a lot more room in the 940.
Have you seen any of "The Fabrication Series" on youtube? - he does a manifold for a forward facing turbo which gave me a few ideas. Trouble is he's made a few manifolds & makes it look too easy!
 
built myself a tool to form the collector tubes.. pics will follow :)

and i bought 309L filler to weld the pipes to the flanges..
 
as promised ;)

The jig works really good actually.. you just have to make sure it is clamped down well in the jaws. Always reproduceable quality of the workpieces!

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do you think it would make sense to tilt the 2 scroll like 5 or 10? to eachother? right now i dont really know how to weld the seams on the seperator thwart. Ot just cram them together straight and dip like crazy to shut them off each other? still no weld on the thwart then..
 
thx! :) i just ran into a wall with the saw.. im not able under any circumstances to saw off a 10? with that wiggly vice from a 2-1 merge :/
 
hm.. thats included shipping almost the price as turbozentrum.de would charge...


naaah.. then it would be bought not built ;)
 
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that truly is a fact! i need a twin t3 flange so i would need to order in the states anyway.. i have looked around for casting merge collectors, also nice but not that machineporny like the part you posted..
 
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