Twin Scroll Turbo

[squaab99t]

When you're done with this job, instead of the turbo being an engine accessory, the engine is going to start looking like an accessory for the turbo.

You won't be cock blocked by the neighboring tube

It certainly will be the jewel of the engine compartment. Form and function.
I'm laying out the primaries with the new modeling blocks. Tricky to get it all to fit with the correct lengths.

I'll update the header construction thread in the big block Chevy. Way sweet car porn. He has all the primaries fitted and tacked in stainless 304.

[KoogiA17]

This is a novel context for the use of that phrase!!

You make some good point regarding utilising a multiple piece manifold flange, certainly will make fabrication easier.

Would never support a turbo using just the manifold. Would be like a cantilever beam of sorts, the amplitude of the vibrations would really stress the welds at the flange.

If you remove the turbo and run the engine should have a Saab organ, place a nice little tune.

[DrewP]

I've had my '85 with headers set up for nearly 10 years, and I don't even have that little stamped support brace that bolts to the transmission installed and have never had a problem with the welds cracking or exhaust manifold studs breaking or anything like that, FYI.


....Which now that I've put that out into the universe, I will probably go out and find my turbocharger just lying on the ground under the car, mocking me...


Dennis - That is bloody awesome, thanks for the updates, very inspirational. (Inspiratorial?)

[Geoff]

How many of those modelling blocks did you have to buy?

[KoogiA17]

I've had my '85 with headers set up for nearly 10 years, and I don't even have that little stamped support brace that bolts to the transmission installed and have never had a problem with the welds cracking or exhaust manifold studs breaking or anything like that, FYI.


....Which now that I've put that out into the universe, I will probably go out and find my turbocharger just lying on the ground under the car, mocking me...


Dennis - That is bloody awesome, thanks for the updates, very inspirational. (Inspiratorial?)

Well....is your turbo currently prone on the floor mocking you?

10 years isn't quite long enough for me! I'm just cautious about these things.

[DrewP]

Haha, I know what you mean. If it breaks, I'll just fix it!

[sjones]

god.. and this guy is in my home town.. he is awesome.

[squaab99t]

How many of those modelling blocks did you have to buy?

Too many, but it is like a wrench set. Needed the various sizes to figure out what works. The 4 cyl longitudinal kit came with the following CLRs: 4",3", 2" and straights. qty (30) each. What is kind lame is that the industry's tubing in 1 5/8" dia U bends comes in CLRs of 3", 2 1/2", and 2". As a goal I opted for 3" CLR since it was an available dimension and 2" seemed too tight of a bend since I had volume to work with. This meant I need to augment the kit with more 3"CLRs. qty (80)
The first layout had some 2"CLRs mixed in. So the at the end of last night's layout. I used only 3" CLR and straights. I "used" a total of 4 * 27= 108

First layout, old and busted:

Second try, New hotness:

What I realized on the second round is that the modeling blocks are like throwing pottery on a wheel. If you "finish" and don't like what you got you smash it back into a lump and then start over. You have not lost anything but some time. Can't do that in real material.

[squaab99t]

Dennis - That is bloody awesome, thanks for the updates, very inspirational. (Inspiratorial?)

god.. and this guy is in my home town.. he is awesome.

Thanks for the props folks. It has been a fun project. Building headers really comes alive when the plastic turns into metal.

[Geoff]

That latest revision looks real nice! It shows what you can do when you have the right tools for the job. It's too bad they're not any less expensive, but molds are expensive especially when they require a collapsible core...

[squaab99t]

That latest revision looks real nice! It shows what you can do when you have the right tools for the job. It's too bad they're not any less expensive, but molds are expensive especially when they require a collapsible core...

The second layout turned out sweet.
Yes, the right tool for the job is often expensive, but "should" save you time, money and come out better in the end. This is a tool that is geared towards the pro or prosumer that plans on making more than one configuration of headers.
Tool rental maybe a more affordable option. Mezzanine has expressed an interest in using my set.

Each block is actually 2 half shells glued together. I'm thinking match metal mold dies and no collapable core required. Just close the die, inject the plastic, and ejector pins to pop them out.

[squaab99t]

Upon final alignment check I found (3) 2" CLRs on number 2 cyl primary. Replaced those with 3" CLRs and had to rebuild cyl 1 and 3 as they were affected.

Sections are taped with only breaks at the joints. From here I can take a tally of bend and straight lengths, and place my order for material.

Bigger picture of the system.

Next detail will be the external wastegates. Yes, that is plural due to the twin scroll.

[squaab99t]

I've had my '85 with headers set up for nearly 10 years, and I don't even have that little stamped support brace that bolts to the transmission installed and have never had a problem with the welds cracking or exhaust manifold studs breaking or anything like that, FYI.


....Which now that I've put that out into the universe, I will probably go out and find my turbocharger just lying on the ground under the car, mocking me...

What is the thickness of the tubing? 10 years is relative. Duty is what counts.

[Crazyswede]

I am pretty sure your header is going to melt

[squaab99t]

I am pretty sure your header is going to melt

I'd venture to say, you would be correct. Although I have some tape on the outside that might help?