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Joel's BRZ

Started by JDWhiteWRX, Dec 12 2016 09:20 AM
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#481 JDWhiteWRX

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Posted 07 October 2021 - 10:17 PM

There is a specific routing as cylinders 1 and 4 are paired as are 2 and 3 in this twin scroll configuration. Then I just did my best to keep each pair equal length. Cylinders 2 and 3 which I did first came out less than 10mm different in length. Cylinder 4 is longer just because it had to go up and over but I have the space to match it's length with cylinder 1. Ideally they would all be equal length but I'm not that good.

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#482 Barbbachello

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Posted 08 October 2021 - 07:57 AM

Amazing stuff


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#483 El_Freddo

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Posted 08 October 2021 - 05:50 PM

There is a specific routing as cylinders 1 and 4 are paired as are 2 and 3 in this twin scroll configuration. Then I just did my best to keep each pair equal length. Cylinders 2 and 3 which I did first came out less than 10mm different in length. Cylinder 4 is longer just because it had to go up and over but I have the space to match it's length with cylinder 1. Ideally they would all be equal length but I'm not that good.


Either way you put my amateur attempt at exhaust work to shame.

Cheers

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#484 JDWhiteWRX

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Posted 09 October 2021 - 07:33 PM

More progress on the manifold, finished making the runners and tacked it all together for test fitting on the car.
 
It's been a challenge for sure but I'm very happy with the progress so far!
 
51567131202_c16951bd18_c.jpg

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#485 RX25SE

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Posted 09 October 2021 - 08:06 PM

Very cool indeed!!

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#486 allpaw4

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Posted 11 October 2021 - 06:14 PM

That is some pretty sweet work, but I am rather curious about how you'll get to the welds when everything is locked in like that. It's something I've always wondered how they do it with it being such a tight space.

Cheers,
Ben

MY00 Red RX, a nice daily that was sold off once the B4 became reliable...
MY02 Blue B4, aka 'The Project' - v8 JDM STi engine package and assorted other 'goodies' - Sold, then bought back for parts. Stripped and crushed.
MY03 Blue RX, the newer old daily, pretty well more B4 than RX now... In the process of being converted to the track toy... Watch this space!
MY02 Silver Wagon, H6 conversion, full blue/black leather and almost full black interior to go with it. In process of being stripped and sold off.
MY03 White/Silver H6 Outback, donor car for silver waghoon. Scrapped.
MY97 Silver RX, acquired to become track car, but plans changed. Scrapped.

MY13 BRG, current daily, very nice to drive, small mods to make it even nicer again.

#487 JDWhiteWRX

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Posted 12 October 2021 - 05:54 PM

That is some pretty sweet work, but I am rather curious about how you'll get to the welds when everything is locked in like that. It's something I've always wondered how they do it with it being such a tight space.

Cheers,
Ben

 

You have to break the tacks and weld each runner separately then fully weld them to the collector and head flange one by one in a specific order. There is some shrinkage but I have allowed for that before I started making the runners.


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#488 Asymmetry

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Posted 20 October 2021 - 05:04 PM

Engineering PhD project, loving it so far.


#489 JDWhiteWRX

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Posted 25 October 2021 - 06:05 PM

The turbo manifold is finished.
 
There are so many hours in this, such a small piece but so complex to fabricate. If I had my time again I may have just bought one but that is not in the spirit of this build.
Having never welded stainless steel before, this was probably not the best starting point and I was certainly outside my comfort zone. I have followed best practice throughout the fabrication, everything was back purged during welding, fit up was tight, some of my welds probably got a little hot but nothing too extreme. I am confident the manifold is going to hold up to many years of abuse even though it is never going to get featured on weldporn.
 
51627508988_bed1e3db86_c.jpg

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#490 El_Freddo

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Posted 26 October 2021 - 07:09 AM

Sick mate! I didnt realise just how low the turbo would sit. Thats crazy low. No dump pipe Im guessing - just a straight pipe from the turbo back?

I spy an intake manifold fitted there too ;)

Keep up the good work, who cares about the welding on the exhaust manifold, you made it!

Cheers

Bennie
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#491 JDWhiteWRX

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Posted 26 October 2021 - 05:27 PM

I started work on the exhaust system today, it's basically a side dump that runs out above the sill. Keeps your toes warm too 😜

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#492 JDWhiteWRX

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Posted 27 October 2021 - 06:01 PM

I've started on the exhaust system, its SuperGT inspired side exit.
 
51632400586_2df6484a29_c.jpg

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#493 allpaw4

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Posted 27 October 2021 - 07:02 PM

Nice! I'm assuming it'll be external gate?

MY00 Red RX, a nice daily that was sold off once the B4 became reliable...
MY02 Blue B4, aka 'The Project' - v8 JDM STi engine package and assorted other 'goodies' - Sold, then bought back for parts. Stripped and crushed.
MY03 Blue RX, the newer old daily, pretty well more B4 than RX now... In the process of being converted to the track toy... Watch this space!
MY02 Silver Wagon, H6 conversion, full blue/black leather and almost full black interior to go with it. In process of being stripped and sold off.
MY03 White/Silver H6 Outback, donor car for silver waghoon. Scrapped.
MY97 Silver RX, acquired to become track car, but plans changed. Scrapped.

MY13 BRG, current daily, very nice to drive, small mods to make it even nicer again.

#494 JDWhiteWRX

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Posted 27 October 2021 - 07:44 PM

Nice! I'm assuming it'll be external gate?


The turbo has an internal wastegate with electronic actuator.

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#495 RX25SE

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Posted 27 October 2021 - 08:18 PM

I love the 'exhaust must go here, so I'll just cut the body away' thinking!!

Imagine the flames spitting out if that, so cool.

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#496 JDWhiteWRX

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Posted 27 October 2021 - 09:46 PM

There really is nowhere else for it to go. Here is my inspiration.

Attached Files


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#497 El_Freddo

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Posted 28 October 2021 - 07:37 PM

Geez, so you’ll basically have an exhaust “in the door” kind of setup? Crazy cool!

What are the requirements for the exhaust? Can’t just do a dump straight out the side?

Cheers

Bennie
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#498 JDWhiteWRX

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Posted 28 October 2021 - 09:52 PM

The exhaust just has to run half the length of the car before exiting, so it will be very similar to that Super GT car above.

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#499 JDWhiteWRX

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Posted 29 October 2021 - 05:00 PM

A video showing the exhaust. I will be adding more to it later, I just needed this bit done so I can start on the steering.

https://www.instagra...edium=copy_link

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#500 JDWhiteWRX

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Posted 06 November 2021 - 07:55 PM

new photo
 
51658325046_5909088f5f_c.jpg

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