Extreme Tuners U.S. Evo Build
Oh I agree with you. If it works it works but still they should have done a better job on that mani. And it still doesn't explain why the transitions and welds werent cleand up though. I mean you could have at least coated it to hide how terrible the mani's appearence is and that way it would hide half the clean up on the welds.
I hope you didn't pay more than $1400 for that header, 02 housing and both dump tubes for the wastegate, if you did, hire a lawyer.
diff size id sections connected due to heat not being controlled in welding.
Yeah I saw that too. I mean I do not want to bash the op, or the vender, but as I said if that were mine and I dished out the funds for that I would be very very unhappy with that.
Can you guys educate those who don't know what to look for when judging welds and build quality of welded parts? Any pointers are welcomed, heck even take that pic and make some marks.
It definitely doesn't look like ToxicFab made it, but that is an aesthetics issue. Good luck with the build. If ET sells you an expensive fuel pump with the pressure bypass punched then you should start to worry.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
Prep work prior to welding.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
and anyone that needs to see the work R/TErnie does, just look at his build thread.. his welds are as good as toxic fabs.
Prep work prior to welding.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
i never imagined so much could be wrong
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Joined: Oct 2011
Posts: 151
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Prep work prior to welding.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
Like cleaning the sharpie marks off the tubes before welding them.
Polishing the bends before welding.
Making a nice bevel prior to welding.
The tack marks are larger than the welds and stand out.
The majority of the welds were not completely shielded by argon.
The beads are not evenly spaced, the same width, and not all are slightly convex. (proper amount of filler)
Furthermore you can see where the heat is inconsistent in the weld by the HAZ.
You can see where they welded the inside and outside of the wastegate flanges as well as on the head flange. This causes porosity in the weld (trapped air) when the manifold gets hot it will expand and cause a crack.
The wastegate tubes where they join the collector were welded too hot and looks like they welded these inside and out again... porosity city. It will fail here most likely.
They welded on some bracing on the wastegate tube to support the gate, I don't think this is necessary and that weld will crack for other reasons that the amount of weight they have hung off it.
They designed a manifold around TiAL V44 gates and not MVRs? What is this 2010?
The turbine inlet flange is not surfaced.
The head flange is not fully surfaced.
The collector is not ported/fabricated very well.
(congrats you actually ported the runners!)
The manifold is not flow balanced (same degrees of bends per runner) and probably isn't equal length judging by runners 1 & 4.
You can see where the wastegate flange arc'd to the table and left a weld POCK mark. Picture #2
Carbide slipped on Picture #3 and weld across the flange while they were deburring their flame cut head flange.
And there is a runner that is retarded close to the valve cover.... I hope they sent a heat shield or some crazy high temp gasket!
That's what I see wrong with the manifold.
