[stackerman]

Originally Posted by corglass

Another questions guys, anyone know where I'd get reasonably prices 2mm ish foil backed sound deadening material?

thanks

I used "Fat Mat" see eBay, last year. Just as good and cheeper (or at least it was then).

[w124man]

Originally Posted by corglass

Being somewhat of a glut for punishment, I've decided to build my own turbo manifold. To do this, I created something similar to a design from IH8MUD in CAD (Rhino3D). (dwg available here.)

I also drew a T25/GT20 flange for a GT2052 turbo. Hopefully this is of some use to someone else. I got the Schedule 40 CAD from here.





I then got the parts cut out using a plasma cutter in 10mm plate steel. Half way through the order I decided that 10mm would be too think for the exhaust manifold connection and I should reorder it in 8mm. When I rang the machine shop guy he said that the piece was already cut out and he'd shave 1mm off each side on the surface grinder free of charge.

I got two manifolds connections and two GT20 flanges cut out. I then assembled everything as per the CAD drawing above, keeping we weld heat as low as possible to avoid warping. It actually held it's shape very well, even if the faces do look a little burnt.



Plasma cut to perfection! The manifolds bits are surface ground on both sides to 8mm, the flange connector is 10mm


Ready for welding!

Some welding underway.

Finito!

Happy days!



Anyway all I need to do now is
- sand the manifold to a clean finish
- find a GT2052 turbo
- mount the turbo
- run the oil lines
- run the boost gauge wiring

:-)


Link to full blog: -> http://bj40restoration.blogspot.ie

Thats a very cool piece of work!