^ Nice CAD layout!

Im no thermo nor materials expert, but their are a couple of factors I would think that are important to the longevity of the manifold. The heat at which it will be running plays an important part. This affects the manifold in two ways (which come to mind right now ) One, the heat exploits any defect the manifold has in its construction. Second, the heating/cooling cycle will expand and contract the metal so any type of welding could (im not saying for sure but it is a source of discontinuity of the metal...ie not their when made ) be affected by expanding pockets of air thus leading to premature failure.

If evidence arose of this type of failure, I would be interested in hearing it. Their maybe great exhaust manifolds being sold on ebay (i dont doubt that) but its the tolerences in respect to heat are those that I am worried about....

 

Thanks. Heat is just one equation. But I guess its the factor that gets it all rolling. You have heat then the weight of the turbo pulling it down as it gets softer. Metal expanding and contracting will weaken it further (usually the weak link) during its cycling period of off boost/ on boost and cool down/warm up. Its pretty viscious. On a tubular manifold that has been attended to in material and construct, it'll give me a little better peace of mind but never 100% as everything is prone to error, especially the inside. I know I'd be hella pi$$ed if something decided to melt off and ruin my GT35R (hypothetically). If you've ever taken off a tubular manifold after some use, you'd find that its shape will not be the same as when you originally put it on. The flange is usually a little warped, some of the runners might've elongated, etc. A buddy of mine had to chisel off a tubular log one time because the head flanged warped to the point that it was stuck to the mounting bolts. One thing that has happened to me was my Greddy EGR probe melted off and destroyed my GT32 a year ago. I datalogged it and found that my fuel filter was partially clogged and I ran into a lean condition up high. My EGT's skyrocketed and burned the tip of the probe completely off. Sucked...



^^^Tubular log. This was some schedule 40 pipe. Very thick and still stress/heat cracks on the piping itself, let alone the welds. He had to chisel this one off as you can see. Look at how thick that material was. He had it coated and was confident that it wouldn't crack. I think he should've at least put some heat cuts on the head flange. This was after 4 months...

 

Holy crap! Safety and surety are my top priorities over performance....like everyone else, I dont have the money to repair damages like these all the time. With the pressures and temps we are seeing by charging 4cly well over 20psi, I believe we must be even more carefull as to the combination of parts we place into these machines

 

My original statements were directed at no one person as they are above... I don't attack individuals on the internet as I believe it to be cowardly when you can not see the whites of their eyes. My retort even included a statement exclaiming myself to be no "authority", so I don't see the merit in that either.

With that said, interesting rendering. It looks to be a cast design (I don't see as well as I used to). I've always preferred a solid cast design over tubular as I've said in the past.

As for your failed manifold pictures, what material is used?

 

How about using that tubular manifold but retaining the stock O2 housing. The stock O2 housing has a support bracket bolt. So it supports the turbo. Therefore, would there not be as much stress on the tubular manifold ? Perhaps better longevity ?

 

That is the way many are doing so... including myself. I have no doubt that the manifold will eventually crack... but I personally believe any tubular design will.

 

it's cheap because R&D part of the build is skipped out. I wouldn't trust my turbo with it.

If the manifold works for one car doesn't mean it's going to work for another car. With that price they could of skimmed out on the quality management as well.

But if it works, haray, you've got yourself a bargain. If it doesn't you've wasted a lot of money to save $200.

 

no worries at all. I hate bickering on the net but I hate when ppl call me out when i'm just trying to have a civil discussion w/ some input on my experience and absorbing other's as well. If I misinterpret I apologize. The manifold is going to be cast in hi ductile class 65 cast iron. Very beefy and won't crack.

The failed mani was constructed of Schedule 40 mild steel as this is the most malleable material when it comes to cracking. The welds were nice and penetrated and fused w/ a tig. Alot of good that did

 

[QUOTE] Originally posted by Zues
I've always preferred a solid cast design over tubular as I've said in the past.

Im starting to see that with TC cars bless my small block for encountering other than header cracking problems lol

 

That true...if my level of tune require 10afr vs joeshmoe's ~12afr, I might have better chances of living through a SStubular for a while longer

 

I am glad I don't have to worry about this ! I'm getting the Boral Manifold with 1,000,000 mile warranty

 

Good for you..... you wanna cookie or something ! By the way the manifold in this thread has a lifetime warranty too........ the pain in the a$$ and the real question here is will any of us ever have too use the warranty. Anyway this subject has been beat to death and only time will tell what happens.

 

Here is what I did to mine to make it stronger...

The bes tthing about it is that you can barely see the welds when you are looking straight down at it. This should really make it stronger.

 

uhm... the ssautochrome mani (man we gotta abbreviate this ****) presumes to copy the hks mani... which means it can pretend to skip out on the r and d. if it works for hks it'll work for them right?. all they did was knock off the hks mani and make it in a thicker tubing.... that said... iunno if it'll break... zeus says his hasn't... that's fine... i don't know what anyone expects as a it will never break manifold... but thick *** tubing sure helps...

as for your cad layup of the cast mani... i think you're too late... buschur alreay has his cast mani and he has one that fits the mitsu flange and the t3 flange.

why not mock up a long tube cast design... that's interesting yeah?

 

i dont know please tell us why.
i just sent out my stock cast manifold, turbo housing & o2 housing to buschur for porting and coating service inside and out ...
and i m kinda worried ,