Log header is done

[turboshad]

I finally got my header done. I think it turned out quite well and should give some decent improvments. I'll be going to the dyno today to get some baselines and then I will change the header and go back to see what kind of gains I got. Should be interesting. Here's some pics for ya.

http://memimage.cardomain.net/member_images/9/web/621000-621999/621520_114_full.jpg

http://memimage.cardomain.net/member_images/9/web/621000-621999/621520_117_full.jpg

http://memimage.cardomain.net/member_images/9/web/621000-621999/621520_115_full.jpg

http://memimage.cardomain.net/member_images/9/web/621000-621999/621520_116_full.jpg

DJ

[tryingbe]

Same stock turbo location?

[The S is Silent]

Looks nice and sturdy. You may want to put relief cuts through the three bolt holes in the bottom of the flange though.

Very nice work. How much did it cost (only if you don't mind me asking)? Did you do all the welding yourself?

[turboshad]

The turbo moves 1" towards the firewall because of the size of the weld els but every other direction is stock. Just looking at the model again and I might be able to squeeze another 1/2-3/8" out of it to bring things closer to the head but I would have to look into it some more.

DJ

[Clay]

cool!!!!!!!!

Hey, can I get a copy of that cad file for the exhaust flange?? :) Purty please!!?

clay

[GLHSKEN]

Definately make the reliefs in the solid bottom flange. Without them it can warp and lever one side off enough to leak. I ran the original ABman and it had that issue. Had to add reliefs.

[turboshad]

Hey, can I get a copy of that cad file for the exhaust flange??

I think I am going to make another 10 of them and see how they sell so I can't really pass on any files. I'll be getting the new flanges made within the month so I could get you one of those if you want.


How much did it cost (only if you don't mind me asking)? Did you do all the welding yourself?

It cost a bit for this one b/c I only made one of each of the flanges to make sure they would fit perfectly before I made any more. It's a good thing b/c I had to make a couple tweeks to get them how I want. The next ones will be just right. Yes I did do the welding myself and and yes I know it's no where near what I would want it to be but the only way to learn is by practice. If by chance you were going to say good job then thanks but it's still not good enough for me.


You may want to put relief cuts through the three bolt holes in the bottom

Yes I am definately cutting the bottom pieces. After that I will face all the mating surfaces to make sure they are true. I was just figuring if I wanted to stress relieve it first in case it wants to move but I think I am just going to cut them and see what happens.

Thanks for all the comments

DJ

[tryingbe]

Projected price range?

[turboshad]

Projected price range?

I'll be looking for about 300 CAD and I think I will also include a new support to account for the 1" movement. (haven't made mine yet but I don't see there bing any problems) I think the turbo support is pretty key in helping a header not crack so that is why I would like to include it.

DJ

[Ground Rat]

I may be interesed in one. What is your setup that you are dynoing?

[turboshad]

I may be interesed in one. What is your setup that you are dynoing?

-50 trim hybrid with stage II from TU
-3 bar cal from Paul pre TU so I'm sure those have gotten even better
-Home built AFPR set to 55psi base for those runs. obviously way too rich
-Cummins intercooler with home built endcaps
-Mildly ported head with 1mm oversized but not deshroud which could be hurting things
-3" madrel bent exhaust with straight thru magnaflow
-standard smart things to do internally

http://www.cardomain.com/id/turboshad

I will post the initial dyno plots tonight when I get home.

DJ

[turboshad]

Here are the plots from this weekend. The three curves are from 13, 17 and 21 psi runs. The 17 and 21 psi were done with the same fuel pressure and the 13 was 2.5psi less static pressure.

http://i54.photobucket.com/albums/g103/turboshad/DynoRun151721HPMay7062forcardomain.jpg

http://i54.photobucket.com/albums/g103/turboshad/DynoRun151721TQMay7062forcardomain.jpg

I will go back after the swap and run the same setup except for the manifold of course.

DJ

[turbo xtc]

looks great and the dyno looks excellent! i need to come up with a good intake manifold idea for intercooling a log

[JuXsA]

I am excited to see the difference.... I have been thinking about getting a Header made.... Where did you get your flanges from or if you made them how much would you charge me to get a set? PM me

Thanks

[Clay]

Looks good! Keep us updated!

[Ondonti]

whats causing the hiccup after 5500 rpms.....The torque curve really drops off after it peaks too. I think you would find more power by lifting the torque curve and you would not need to increase boost Considering the 13 psi doesnt drop off so violently I would guess that you have a bottleneck to fix that would bring out some huge power on the same 17 and 21 psi boost levels.

[turbovanman²]

Awesome work, can't wait to see the dyno results, :thumb:

[turboshad]

whats causing the hiccup after 5500 rpms

I was getting some kind of miss in the upper RPM. My guess would be a relation to that and the stupid rich A/Fs.


The torque curve really drops off after it peaks too

Ya, I'm going to start by leaning it out and doing some data logging with the wideband to help try and smooth out the A/F curve. I should have my computer EEPROMed soon as well which will also give me more control. You are right though, if I can level out the torque curve then my 300hp goals should be easily met. I'm pretty sure just playing with the fuel will net some good results. Unfortunately I will have to run it stupid rich again for any header swap info to be any good but what's a guy to do.

DJ

[89turbomini]

Work looks great! Where did u ge the metal 90 degree bends and Tee's from?

[Wink]

I must say. That manifold looks alot better than the one I fabricated. Good work!!!

Lets see some numbers from that monster.

[turbovanman²]

Any update on the header dyno numbers?

[turboshad]

Any update on the header dyno numbers?

Funny story about that. I booked a dyno appointment but then noticed I had a leaking valve seal. I decided to fix it before the pull and I screwed up and didn't get the keepers seated. Not a block after I left for the dyno I dropped a valved and took out the engine. It wasn't a happy day. I was quite dissapointed I didn't get to dyno the header not to metion I just killed my 8V. More on the story here..

http://www.cardomain.com/ride/621520/7

But on the plus side it pushed my 16V project alond and I expect to be driving that by late June. Once that is done I will still be making a few more headers to try to sell. Here is the progress on my currrent project.

http://www.turbo-2.com/forum/index.php?topic=162.0

DJ