No major updates just yet, just a little more work on the crossover. I cut the rest of the old flange off of the passenger side entry into the turbo manifold, slid one of the clamps onto the crossover, then grounded down some of the weld on top of the now joined the pipes. The weld is looking much better, despite not even being able to see it when it's bolted to the engine. I have the universal Walker made ball flange sitting in the box, and finally got my welding mask back, so I'm gonna try and get that finished up tonight making the crossover done.

 

updates?

 

Headers are done, and I am happy with the way they came out. Still need to plumb the wastegate flange in though, and I am still thinking about where I'm going to do it. The inspection for the car is up this May, so I want to get it inspected again before I start pulling everything off because we still have visual inspection here. Once I get that wrapped up everything is going on...

 

Oh ok cool you got pics of the headers done and did you end up doing it with A/C or no A/C?

 

probably no ac, this is strictly a race car yes?

 

No air conditioning, running an a/c and smog pump delete pulley(s). Also scrapped the v-belt setup and stood with the stock serpentine setup without any modification to it, had to clock the turbo flange so that the turbo slightly faces the coolant resevoir area. Wastegate location is still pending though. I'll have pics up soon, as the weather is finally getting closer to the 60's...

 

I keep forgetting to update this thread in stages. This is how the header setup looked just before I welded the Walker universal ball flange onto the passenger side inlet to the turbo header. Disregard that motor, was just using it for the mock up...

 

you could go back and edit your posts and then leave a post describing how you edited the thread and it was now in the events in which it happened, idk just an idea

 

rob man lol what happened when u welded the air fittings up, looks like the welder sneezed on the tubes lmao.

did u use flux cored wire on that or something?

 

Those were done when I was still welding one handed, it was impossible to hold the welder, the mask, and an aluminum block that I use to fill holes all at the same time...

 

It's a good idea! Honestly though, I think those who are following the build will be able to follow everything in chronological order either way...

 

what do u mean an aluminum block? did u stuff a piece of aluminum in the holes? if so i would cut them out and redo them they will not hold

it is a pain in the *** to weld one handed my mask is a handheld mask and i did all of my turbo system on my car one handed but i also have many many years welding experiance lol and its still a pain in the ***

 

Man looking at this I need to start making a turbo header for the passanger side of my car.

Getting there though Rob, cant wait to see it when you get it all done up.
Get up on the weld closer when you using that hand held shield, you can guide your one hand with your other arm, or litlerly hold you welding hand aginst your chest while you lay the bead, just make sure your wearing the right stuff to not catch on fire.

I had to use one of those hand held shields when arc welding..That was a PITA

I just went so dam* slow that the metal is beating red. I was using gas though, but still I know my welds are so tight since the welds were dripping hot from going so slow, but was sealed up tight as can be, from the gravity of the weld, and the temp of the metal just sinking in to the joint.

Just my 2 cents as Im not real welder.

 

No, that's not what I meant lol. When I weld up holes, I hold an aluminum block on the other side of the hole when I am welding steel, or hold a brass block on the other side of the hole when I am welding aluminum. The weld will grab the sides of the hole and fill the hole, but the weld will of course not grab the block. Pull the block away, the hole is covered, then I smooth it down...

 

one handed and flux core or not, you need to put the welder down. Sorry but a blind folded 5 year old can weld better than that. get some scrap and practice for HOURS before you continue... And just becasue the welds are big and built up then "smoothed" down doens't mean they are strong or sealed well. Also it looks like your anre not grinding/cleaning the pipes very well before you weld, thats welding 101, come on man....

 

belive it or not thats the worst thing u could do rob. much better off not putting anything behind the weld and then using a die grinder to clean up the inside

 

check out some welding vids on youtube. i like to watch weldingtipsandtricks.com. very informative... you can learn alot just from watching someone weld. i recently have learned to tig weld by watching his vids and practicing with the welder at work. i've gotten pretty dang good at it now, to the point where i can weld thin stuff without a foot control. (our tig rig is just an add on to a big ol' miller dimension 350)
took some time getting used to running the torch with my right hand and adding filler rod with my left hand. at first i was blobbing up the tungsten like crazy, but now i hardly ever have to sharpen it.

anyways, how thick are those tubes? they look to be at least 16 ga.... pretty thick. mig should work fine for that, but you have to be careful not to spend much time on the butted area between the tubes your welding. you'll blow a hole if your running a good amount of heat on it.

 

Listen, that is the second time you commented about something without reading ahead of time. First you comment about the flake from the flux destroying the turbine, which of course made me laugh out loud, but despite that you say that without reading ahead of time that this set is getting coated in the end, which of course would remove any remaining residue from the flux inside of the setup. Now your commenting on the welds when you have no idea what your talking about. My welds are fine, everything was ground down before hand, it had to be because it is aluminized. Even the welds that were welded one handed, the penetration was good, and they were all smoothed down flush, inside and out. I can honestly appreciate the criticism, in fact I encourage it, but if your going to try to criticize something without first reading ahead of time, then that is more 5 year old with a blind fold oriented then anything else...

 

Meh, as long as they are filled and are strong I am happy. Those three pictures showing those welds were from awhile ago, everything was ground down, inside and out, and are strong...

 

The Edelbrock's were listed as 16ga when I bought them awhile back, but measuring them revealed a tad over .070", which was odd. I doubt the early Edelbrock's were 14ga, but hey, I'll definitely take the added thickness either way...

 

i will just comment on the stuff posted earlier, it's pretty ugly. lol
we get alot of stuff in at work that will have welds similar to that. many times you can take a 3lb. sledge and smack it a couple of times and ding there goes their weld. normally when its all piled up like that there was no penetration. -which is why they had to keep piling the weld on, so their bracket or whatever would stay on there. also. you can cut a nasty weld in half and it may resemble swiss cheese. full of holes.

but hey, its just welding and everyone can improve on their skills. people arent saying your arms are too short for your body or whatever. you wouldnt be able to control that. lol

 

The actual process was filling it up on the outside the way you seen them in the earlier pics above, as that was of course done so when I welded on the inside the weld had something to grab onto, then once the welds were filled and finished on the inside, the outside was then grounded down flush like you see in the pic three posts up. I will post a picture of the finished setup soon, I am posting this in stages for you guys. If I was worried about how it looked during the process of putting them together, I obviously wouldn't bother posting any pics...

 

i welded some turbo headers together a few years ago using a lincoln mig 125 with unimix welding gas and .026 wire. cut all the pieces, tacked them together, then welded it all up. turned out great, but once i was done i had no faith in the 18ga. material i had used so i never used them.
grinding all the welds would take a looooooooot of time. i had plenty enough time in them just doing it the way i did.

 

 

I wish you would have welded up all my exhaust and charge piping

 

i know that took u forever since u put lil tacks all the way around the pipe until u got all around , why not just weld it continously ??? or were u haveing problmes burning threw ?

 

Very nice! When is your turbo setup getting done Dig...?

 

i didnt weld that guys, i just found the pic and tossed it up. its from burns stainless i think. honestly, i think it could be better than that.... it looks great, but the little divot in each of the "dimes" makes me wonder. i know when tigging without a pedal its easy to leave a divot like that. not something you want, and pretty isnt always the strongest/best weld.
anyways, i just tossed it up there to look at.

 

... you had everyone ooohing and ahhhing, me included.

 

that is not a tig weld, notice the brown around the edges tig would not do that at all its a mig weld

the divot u are refering to is because it is nothing more then a bunch of tacks around the outside of the pipe. alls that is is holding the mig gun trigger on for 2 seconds then quickly move to the next spot and squeeze the trigger for 2 seconds.

that weld will be weak around the outside circufrence of each tack/weld spot, the divot is created from the arc still going while no more wire is being fed in.

normally u would only see that divot at the very end of the weld

 

I said slag, not flake Mr "read first" You clearly do not want to listen to anyone even though multiple people are trying to help you out, so I'm not even going to wast my breath.

I dont think I need to comment on you telling my I dont know what I'm talking about in respect to welding. I've been doing analysis and lab testing on stick and mig welds for the last 2 months LOLOLOL But it looks like you know what your doing so I wont explain why your welds are not adequate. Sure they may work but they are badly flawed...

I will say it again, put the torch down, read, and practice then start on the car again. Many people on here are trying to help you and you refuse to listen. Your current welding technique is only going to make things harder and cause you problems down the line.

 

There is a tremendous difference between constructive criticism, and just trying to be condescending. Again, I can appreciate the criticism, in which three other member's did along with you, however again, there is a tremendous difference between constructive criticism, and a condescending attitude. Incidently, "slag" is essentially ash, and as it flakes off in pieces, it will blow right through the turbine. But again, I am getting this set coated inside and out, so I am not worried about that. As for wasting your breath, your choice either way...

 

ok getting technical here, the spatter is what I was refering too, i just refer to the spaltter/slag combo as slag since they are both unwanted byproducts of the weld.


I'm gonna refrain from commenting on your "additude" discussion or whatever point you are trying to get across, this thread is not place for that - we can take it to the bullet if want though

 

The spatter is ground down after the slag is removed with a wire brush...

... and yet you go out of your way to post in my thread again after not wanting to waste your breath lol? Do yourself a favor, go grab that hose of yours, place it between your legs like you so thoroughly do, and cool yourself off.

... pm me, and we can take it to the bullet all you like.

 

Don't pay any attemtion to these guys who only have negative things to say. The way I see it if one person mentions it thats all that needs to be said. for them to keep going on and others to join in is stupid. If it were me I'd just kick them off the thread so they can't make comments. I think your doing a good job and will continue to read your thread. Good luck with the build.

 

Thanks Pat. I honestly enjoy the criticism, the more the merrier, and I take it all in. The one handed welds look horrible, I would be the first to say that, in fact I even said that pages ago when I said please excuse the welds because they were one handed. It will all look nice and pretty once it is coated, the welds are already smoothed. I got my hands on two 90 degree bends awhile back and I didn't even bother using them. I had an old Flowmaster exhaust that I hacked up awhile ago, and took the needed pieces from that. This pic is from when I was still mocking it all up. I didn't like how the BBS turbo header had the primaries entering into the log straight in, as I wanted mine curved and flowing straight towards the turbo flange, and that is why I didn't use the two 90 degree bends, rather I used just one 45 degree bend that I cut from the Flowmaster exhaust...

 

Harbor Freight has an Auto darkening hood that works good if you have the room to use it.

 

There is a guy in MA that has an '86 Iroc 305 in the 9's single turbo. He is at New England Dragway every so often. Good guy.

 

you are a child...

 

Well, this child, as you so insinuate, doesn't fill your individual build thread with incoherent babble being disguised as some type of coherent point. You said what you had to say in my build thread, and I said over and over again that I can appreciate the criticism, but there is no need for you to post anymore in this thread because you are doing so just for the sake of responding, while contributing absolutely nothing. If you have something to say to me, personally, take it to PM, okay. Otherwise, do me a favor and practice what you preach, that being don't wastE your breath anymore...

 

Is it Preston Smith...?

 

I was such in a rush to get out of there that day it didn't even dawn on me to look around for one. I do have my mask back though, it isn't the greatest, but it does allow me to weld with both hands again...

 

me and rob have known each other for years, he also knows the kinds of stuff i used to weld and build for a living. so im not here to just give negative opinions

 

Rob I know your not letting people get to you on this build. Your doing a great job man! I cant wait to see your finished project!

Off topic sorta, but what route are you taking on the Intercooler?? I really wish I had the money for alky injection. You thinking of going that route as it sure would help you make some great boost!

What are you going to be tuning the car with.... modding the stock ecm tunes or somthing else?

 

Yeah, we definitely go back man. If you lived closer these freaking headers would have been done a long time ago. I am so done after this build though, it is even funny anymore...

I have the same I/C that Dave is running, the 4" eBay one for a little over a hundred bucks. I spoke with Julio (Razor Alky Control) about an alky injection setup last year, but GM discontinued the resevoir that he uses, and rather than wait around I just decided to run E85 instead. I already have the DW intank fuel pump for E85, I just need to get larger injectors to be able to run that fuel. Tuning will be with the EBL P4...

 

u could have just bought a set of my twin turbo headers and been done already

 

You should make a set with serpintine belt

 

i would if i had a serp car to do the fab on, i do belive my current tt headers would clear just by rotating the ds turbo flange out twards the fender slightly but i cant be 100% sure

i do know that the headers will clear a vbelt ac setup though, i just happened to ditch my ac, though im kinda regretting it i do live on the edge of the desert lol

 

Do you have any pics of the turbo with the AC i wouldn't mind downgradig if i could keep AC lol i live in Cali and when the girl is in the car i want her to be fresh lol.

 

i dont think i took any pics but i think my ac compressor is in the trunk of the car still, if it is ill throw it back on and take some pics