Mock up done.......

[Chuck Leeper]

Got the last piece of tubing tacked in place. Next is to check the fit on the 85, one more time. Then, it's finish welding time.
I may add a flex joint after I check the fit when it's finish welded. I'm sure it'll move some.

All 304 stainless, except the turbo flange. [T4].
Comments??

View attachment 168989View attachment 168989

 

[TR Custom Parts]

Looking good! Love the lightweight FedEx balancer.

 

[Chuck Leeper]

Looking good! Love the lightweight FedEx balancer.

 

[BGNeXtreem]

I'm interested when your done and want to make another set keep me in the loop

 

[BandAid]

I gonna ditto that,-------- can i send my manifolds and have you do me a setup like that.. very simple and to the point,looks great

 

[8 SEC 109]

Chuck
You make it look sooo easy! Great work!

 

[TurboBuRick]

Looks good Chuck. I would make a bracket to the t4 of the head to hold it in place for welding. Like you said, it's going to move.

 

[gnfanatic]

Chuck, you talented man you. I need to take a road trip to GA one weekend.

 

[Chuck Leeper]

Chuck, you talented man you. I need to take a road trip to GA one weekend.

ALWAYS ready for some sweet tea and pulled pork!!

 

[Chuck Leeper]

Looks good Chuck. I would make a bracket to the t4 of the head to hold it in place for welding. Like you said, it's going to move.

That's next. I'm also working on the w/g piping and a flex coupler.
Once this is all done, I'll have to help somone put an LS in thier TR, so I'll have a place to test it out!

 

[Chuck Leeper]

Chuck
You make it look sooo easy! Great work!

Thanks! NOTHING like the stuff you guys are turning out, tho...!

 

[Chuck Leeper]

Just welded the first 2 split flanges to the pipe. I made an aluminum heat sink, to help reduce warpage in the flanges. Seems it's working.
Here's a couple pics showing it's effectiveness. Note the discoloration where I had to weld about 1" without the sink attached. A significant concentration of heat, vs the sinked welds....
The sink is 1/2" alum plate. It works! I checked temps w/ the IR gun...Even with 1" weld runs, the temps were well over 120*.
Pipes are coated w/ Solar Flux, prior to welding.

 

[BGNeXtreem]

I knew you were a pro nice

 

[TurboBuRick]

Nice weld bro! Great idea with the heat sink.

 

[Chuck Leeper]

Thanks!

 

[Chuck Leeper]

Update: the current pass side mock up failed to clear the frame. I've since cut it off, recut the manifold to turn the pipe more toward the engine, and up a bit.
I'm also looking at the poor match of the split flange to the odd shape of the manifold...NOT good for smooth transition into the pipe. [Manifold has a "pear shape to it.] Matching a 2.5" round flange is a BAD choice. I've made an oblong end on a bend, that matches the contour of the manifold. This puts a "collector" on the manifold, and greatly reduces turbulent flow. The dr side needs some "porting" work on the manifold side of the split flange, to help w/ this, too. Next gen will have the "collector" used on it, too. [Already welded.]
A couple pics...

 

[gnfanatic]

I am glad all the years I taught you how to weld finally paid off

 

[Chuck Leeper]

I am glad all the years I taught you how to weld finally paid off

Me too!!

 

[Chuck Leeper]

Well, the "mock up" didn't do so well... Seems as tho there were a couple problems w/ the fit!
Too high for hood clearance.
Angled to match engine install angle...NOPE!
Too close to the core support.

Cut it apart, dropped it 4", rolled it out toward the inner fender, moved it back 2", put it level w/ the ground, and square w/ the ft face of the head.
Results: Over 4" hood clearance, plenty for air intake tract, space for the w/g.
All has been tacked together, along w/ a flex coupler. Back to in- car fit, and finish weld. Will fit the w/g and bracing, next.
Then, next stop is the bender, to see if we can't make this in 2 pieces.

 

[Street Lethal]

Damn good work, looking awesome Chuck...!