Gasket match on exhaust header to turbo

[OO]

This is the worst match I've seen in a while. Just screaming for a die grinder.
#ad

I also have some pics of my latest project, an equal length tubular header. Didn't get to far yesterday but it should start to take shape by the end of today. http://albums.photopoint.com/j/AlbumIndex?u=1506659&a=11375901

 

[HEMI®Dart]

Thats terrible. I saw that too when I matched my gasket to the turbo housing exhaust. If that were a gasser head there would be a 25 HP gain right there.

00,

What are your thoughts on grinding those raised bosses inside of the exhaust housing flush with the walls & Roof. Do you think we will break thru?


More info here if needed: https://www.turbodieselregister.com/ubb//Forum3/HTML/002178.html

Are you going to weld together a header type exhaust manifold with those pieces of pipe? Post some pictures of the finshed product. #ad




[This message has been edited by HEMI®Dart (edited 02-04-2001). ]

 

[OO]

Once you get past the flange(about 1/2" thick) the casting is around a 1/8" thick or so. Not much room for a proper cleaning up. Most of the the material removed would have to be in that 1/2" area.

Added some more pictures from today. Didn't get to far just finished the jig.
http://albums.photopoint.com/j/View?u=1506659&a=11375901&p=40107452&Sequence=0&res=high

[This message has been edited by OO (edited 03-08-2001). ]

 

[Joseph Donnelly]

Uhhh, its not a gasser. Its a Cummins turbodiesel. The choke point is farther inside the turbine housing where the 12, 16, 18. 5 cm2 measurement is made. Everything ventured, nothing gained. Don't waste your time. My outlets and turbine housing are STOCK, enough for 510 hp. If you have the itch to grind, take the head off and work under the valve seats. #ad

 

[drawson]

But Joe You could have been at 535 had you gasket matched. Sickly deserves better LOL

I did mine manifold to housing when putting on my 16CM2. I can't hurt, just cost some time. I also did the inside of the elbow.

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EAT'M UP
97 2500 Club 4X4 3. 54, Forrest Green/Driftwood, LSD 5 speed, & Psychotty Air System, TST #11, 370 HP injectors, timing at 16 deg. , 16CM2 housing, AFC spring kit, Geno's Exhaust Blanket, TST EGT gauge & 0-60 boost gauge in A Pillar, Cat-be-gone, 4" Dynomax Bullet muffler, Crome 4" turn down, Rad fan removed, AmsOil Through out, Geno's trans filter kit, AmsOil Bypass system, Lund Winter front, Leer Cab Level Shell Driftwood , 255/85R16, Dyno'd 342 HP pre injectors & turbo housing *NRA/USPSA member and proud of it*

 

[OO]

I have seen pictures of high performance gas and diesel turbocharged vehicles and they both use custom made tubular headers. Check out this pic.
http://www.turbomagazine.com/images/main03.jpg

[This message has been edited by OO (edited 03-08-2001). ]

 

[jmeehan]

How many headers do you plan on building? You know most people here will want one.

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ex Ford tech, now driving '01. 5 2500 4X4 QC LB ETH/DEE SLT 3. 54, Patriot Blue

 

[OO]

If the first one works out I'll make another one with the bigger flange for the H2E turbo. Then I'm going for the twin sequencial turbo header.

 

[Steve Campbell]

Just a thought, the heat loss between head and turbo = less force spinning that thing. Use heavy material or get an exhaust blanket. I made a number of different connections from the exhaust housing to turbo on a VT903 before coming up with something that would retain heat and last 2 or 300,000 miles.

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1999 Qcab 4x4 Driftwood
Steve

 

[sport bike]

OO,

I don,t think you need to make up a header,but some porting wouldn,t hurt. You need to look up in the port about 3ins. That is where the biggest restriction is. If you think you ground it down to thin,then braze the area up. Or you should try the ATS manifold.

John/SP

 

[Vaughn MacKenzie]

I don't think it's super duper airflow & volume that OO is going after, but smooth, even airflow. I doubt you'd see much of a gain on the dyno compared to the stock manifold but certainly it could help with turbine spoolup. Even with the ATS manifold I don't think you could get the nice even air pulses that you would with an equal-length tubular header.

Vaughn

 

[BPINE]

Well I matched mine up it might not be the biggest part of the restriction but it is not good to hit a raod block either.

 

[OO]

I'm using 1 1/2" schedule 80 tubing. It's about a 1/8" thicker than the stock cast header.

The ats header is nice but expensive. The one I'm building will cost me about $100 in parts. That leaves me with a little extra for Joe D's new clutch #ad

 

[John]

I gasket matched/port matched both the inlet and outlet of my ATS exhaust manifold and inlet of my Banks 14 cm2 turbine housing prior to having the inside and outside of these components ceramic coated matte black. It may not add any real HP although, attention to details such as these are what pay off in cumulative dividends. #ad


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John Treibel
'98. 5 2500 QC 4x4 Sport, Glasstite Vision II, 285 BFG A/Ts on M/T Challengers, Warn 4X Boards, Mopar fender flares & tow hooks, NW Custom s/s-rubber mud flaps and accs. , Mag-Hytec diff. cover & trans. pan, Edelbrock IAS shocks, Reese Titan V hitch, SPA gauges (3), Dynamat, '00 Sport grille and headlights/PIAA Super White bulbs, PIAA Dual Sport 900 aux. lights, BD exh. brake, Amsoil Dual Remote Bypass, Optima Yellow Tops, DD3s/DD Boost Module, Aeroquip AQP braided s/s fuel hoses, Banks High-Ram intake manifold and 14 cm2 turbine housing w/Big Head wastegate actuator, ATS 3-piece exh. man. , Banks 4" dia. s/s exh. sys. , DTT 93% TC, DTT custom tuned VB, BD modified trans. front pump (enhanced by DTT), Air Bulldog induction hood (with NACA ducts), plus MANY other trick modifications

 

[Joseph Donnelly]

You might check boost psi vs. backpressure (aka turbo drive pressure) in the exhaust manifold. With the HX40/18. 5 the backpressure is usually lower than boost, even with those nasty as-cast surfaces #ad

Just think--you want the gases to expand in the turbo, not at a port mouth where they then have to contract again, etc. The ideal situation would be uniform cross section all the way to the beginning of the turbo scroll where its size is measured (like 16 cm2). Thus, I think there is an easy explanation for why folks who have bell-mouthed the exhaust manifold to gasket size, etc. lost some response.
Dee, I agree, Sickly deserves better. He already is there #ad
And, with as-cast turbo matchup #ad

 

[OO]

What are you using to measure backpressure? I would like to get some readings before and after.

 

[John]

..... no bellmouthing or response problem with my gasket match/port match job Joe. Unlike most, I have been porting heads and intake manifolds off and on for over 25 years now. As I have had thousands and thousands of hours of die grinder experience, I'm confident that my latest job was my best work yet. I didn't just hog out the exhaust ports without consideration to cause and effect. I have specialized equipment that allowed me to reach deeply into the exhaust runners/turbine housing to effect the changes I deemed necessary. As a matter of fact, the ceramic coater saw the before and after porting work and commented he had never seen better more accurate work. As for head to exhaust manifold to turbine housing alignment... it is EXACT (I checked it with Prussian Blueing several times). So you see Joe, some of us didn't just fall off the turnip truck.

[This message has been edited by John (edited 02-08-2001). ]

 

[illflem]

OO,nice to see that someone besides me has found a use for used snowplow guards.
My county road yard has a pile 10' wide and 6' high,they told me I could have them all.
They have become one of my farorite steel stock,very good steel.

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95' 25004X4,AT,Driftwood,Banks Stinger,Warn fender flairs and running boards(work truck)
95 3500,5 speed 3:54,BD E-brake,Driftwood,Banks&Psycotty,34,000 GCVW apple and tractor hauler(works harder truck)

 

[NVR FNSH]

Do the higher rated ISBs use a less 'restrictive' exhaust manifold? Just a thought... .

 

[Joseph Donnelly]

John, no offense meant. However, why bother with all that porting and then cram the gases through a 14 cm2 exhaust housing that is about like a 1. 6" diameter pipe? Remember, that size is for BOTH ports, so the size at the choke point of th scroll is half that for each cylinder. I'd understand why you went to the effort much better if you were trying for 500-600 hp and using at least an 18. 5 cm2 housing (1. 9" ID, 2"OD pipe equivalent).

I'm not trying to criticize; I just don't understand your purpose here.