Turbo V6 Dakota Build.

[Mopar318]

I am building a tubular turbo header for a V6 dakota, I know alot of you on here also have dakotas so I thought I would post this on here. I am just building the header, the guy Im doing it for lives in california, so I cant really mock anything else up on my truck because of the slight differences in the trucks.
Turbocharger is Garrett GT35, utilizing a external 38mm tial wastegate.
Check out my awsome homemade collector jig! Buy it for a one time low price of $499.99!







BOO for stupid port shapes. Something most the import header buidling guys NEVER have to deal with.

[black86glhs]

I was thinking you were talking about the six pack when you said custom jig....
Nice work.

[Mopar318]

[Vigo]

keep up the pics, i wanna see where this goes. My dad's got a 96 3.9 we've had since like 97 and one day i may get around to messing with it since its pretty much extraneous nowadays.

[black86glhs]

So the spacing on the cylinders is the same between the 5.2 and 3.9? I know the 3.9 is supposed to be be based off of it.
Not trying to imply you would build it wrong, just asking.

[GLHS592]

So the spacing on the cylinders is the same between the 5.2 and 3.9?

Yes it is.

[Mopar318]

Yes they are virtually the exact same with 2 cylinder cut off the front. Same bore, same stroke, same cam lift, same valve springs, pistons, rods, etc.......

I might finish it tomarrow if it warms up a bit.

[Mopar318]

Overall look, need to cut down the collector pipe to lower the flange, and shorten the runners, I dont like how long it is.

[Dez]

Looks good, mild steel?

[Mopar318]

Looks good, mild steel?

yes, it will be ceramic coated.

[moparzrule]

Hard to tell, are they 1 3/4'' primaries?

Looks nice.

[Mopar318]

They are 1-5/8" primaries into 2" then into the collector

Made some alterations

[moparzrule]

So you are going to run the driver side feed to the turbo from the firewall side instead of the front of the engine?

[Mopar318]

So you are going to run the driver side feed to the turbo from the firewall side instead of the front of the engine?

Yes the crossover runs behind the engine, He is going to have an exhaust shop connect the crossover to where is y-pipe used to be, and build his downpipe. Those are things I cant mock up on my truck do to the different transmission.

[Mopar318]

its done minus wastegate pipe.

[8valves]

Neat stuff. How did you weld the insides of the two grouped primaries on the head? It would make it so that you wouldn't have welds lined up, but you could make the #2 (from right to left) primaries first piece longer to sit out so the weld is where the bend in #1 is to make it easier if you do another one.

Just a thought. I bet a turbo Dak would be fun. Your 318 truck would've been a blast!

[Mopar318]

Neat stuff. How did you weld the insides of the two grouped primaries on the head? It would make it so that you wouldn't have welds lined up, but you could make the #2 (from right to left) primaries first piece longer to sit out so the weld is where the bend in #1 is to make it easier if you do another one.

Just a thought. I bet a turbo Dak would be fun. Your 318 truck would've been a blast!

Once I tacked everything I pulled the tubes and welded them all individually, then stuck them back on the flange.

On the inside I push the tube in level with the flange, Welded it with a small amount of filler and ground it flat. Its how they do all the headers from any of the other companies so I think It should work out fine, Im also going to run a bead on the out side as far in as a I can. Sometimes its hard to work with thinner tubing because its so easy to burn the carbon out of it.

[8valves]

Once I tacked everything I pulled the tubes and welded them all individually, then stuck them back on the flange.

On the inside I push the tube in level with the flange, Welded it with a small amount of filler and ground it flat. Its how they do all the headers from any of the other companies so I think It should work out fine, Im also going to run a bead on the out side as far in as a I can. Sometimes its hard to work with thinner tubing because its so easy to burn the carbon out of it.

Ah, so you break the tacks from the flange and collector then put them back in... right on. That's all I was curious about. That's why slip fit collectors are so nice

[Aries_Turbo]

you gonna make another tubular one for the other side i assume and have the exhaust shop do the connection?

they gonna cut and weld mandrel bends together?

it would be a shame to go to all that trouble for some nice headers and have some crush bent in there.

Brian

[Mopar318]

Well its not a full slip on, Its a formed collector you have to weld the star in the middle of the tubes and then weld around the collector.

A slip on burns collector would cost more than whole header alone, and then I would want to use some 321 instead of mild to go along with it.

Unfortunaly, its not my money to be making the desicion.

Im still trying to figure out how the Burns slip ons are fabricated, I know they are CNC welded, but how friggin small is the welder to fit inside the tubes like that.