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Her kan du se et eksempel på hvordan en turbomanifold kan laves. Guiden er fundet på nettet (engelsk).

-> Custom made turbomanifold, af Arne Bang, Norge

The flange are made of 10mm thick steel. I used a stock gasket as a template and drawed the shape of the gasket on the steel plate with a waterresist pen. Then i drilled all the holes for the bolts and got a friend to drill the holes for the exhaust ports with a cnc controlled machine he has at work. I grinded the outer edges to shape with with a hand held belt grinder. The pipes and bends are regular steam pipes with an inner diameter of 37mm and a wall thickness of 3,5mm

As you can see i have welded on the first 4 bends. The reson why i didnt just stitch them in place at first are because if the flange was the last item welded on i would have serious problems with correcting the distortions caused by the welding.The flange are now corrected and are free from distortions. I prefer to make the welds to the pipes at the flange last since that would not twist the flange to much.

Since the exhaust ports are oval and about 8mm wider than the pipes i had to flatten the pipes sligthly and
put them in place with small welds on top and at the bottom. When all pipes was in place i heated up the pipes and stretched them to each side with a ball headed hammer, when this was done i could weld them properly and smoth out the surface on the inside.

At this pic i has spotwelded the 2 center pipes together.The 2 outer pipes are also testfitted and spotwelded

At this pic the center section are welded and the 2 outer pipes are welded together but just fitted to the pipes from the flange.

All welding to the pipes are done.Some heating and bending are required to collect the 4 pipes in a proper way.

All pipes bended together and welded,both from the front and from the backside

Same step just a different angle

The conical tube from the first pick are cut down to size and first spotwelded to the 4 pipes then i heated it and shaped it with an hammer before i welded it completely together.

The flange for the turbocharger was included in the package and are welded on too. As you can see i have also sandblasted the manifold, not just for looks but also to reveal leaks and small cracks.

Test fitting the Turbocharger before getting the flanges milled true.

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