Top Mount Manifold Build

[Lucient]

I have been wanting to build a top mount manifold for quite some time now for my KA. I finally decided to bet the supplies needed to build one at minimal cost. I chose mild steel over stainless steel because of the price of the materials and I dont have a welder that will weld stainless. Im using a mig wire feed welder to weld this thing up and it should do the job in 2 passes. I made some test welds with 2 passes and took them to work and let our Certified welding inspector ultrasonically test the welds and the welds had great penetration.

Materials Im using:
12 1 1/2" 90 degree but weld els
2 1 1/2" 45 dergree but weld els
5 feet of 1 1/2" schedule 40 mild steel pipe
1 1 1/2" schedule 40 mild steel 4 to 1 merge collector purchased from BMCrace.com for $40. It was cut precisely and the pipes fit together perfectly
1 T3 mild steel flange from BMCrace
1 KA 1/2"thick mild steel flange


Total cost for materials was approx $150. Pipe and elbows were purchased from easter plumbing distributors in Buford GA and the elbows run about $5 each.

Tools used:
Abrasive chop saw
4 1/2" angle grinder
6" bench grinder
tape measure
dial caliper
120 volt mig welder with shielding gas




First thing I tackled was the head flange. It wasnt one the fancy laser cut units so I had to de-bur the ports and had remove some material on the head side to get the flange to line up with the ports in the head. I would recommend getting the flange from BMCrace that is ported to accept the schedule 40 pipe. It makes things much easier.
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02037.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02038.jpg


Next was the collector. It came from BMC race perfectly cut and was an easy fit. I tacked it together and then cut the top where the turbo flange would be mounted
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02034.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02035.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02036.jpg

Here is a jug I made to cut the top flat
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02039.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02040.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02041.jpg

Then I tacked on the turbo flange. I was told to put bolts in the flange when welding it so the holes dont warp.
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02042.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02043.jpg


Next I started on the runners. The first runner is a PITA and I had several cut and re-tack trial and error fittings but I was patient and got it going. It helps to have someone else to help hold stuff.
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02044.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02045.jpg


And this is as far as I have gotten. I will keep this thing updated as I progress. I will be happy to answer any questions

[hoa]

nice! :goodjob:

[de3zy]

i cant believe i can post on the diy threads... whoa..

anyways.. good post. im so ready to build one... once i get a turbo..lol

[babowc]

nice.
I've seen ya posting on KA-T.org and you're making really good progress!

[Casey]

good stuff man :)

[JDori]

bad ass looks like a good start...

Keep us updated... u might be able to mass produce

[hellfire]

Why didn't you just cut the flange off an SR mani and weld a KA flange to it?

Tyler

[JDori]

daam never thought about that before

[Zippy69]

Nice job. Looks like it will be a well built manni.

[Koukidrftr]

Why didn't you just cut the flange off an SR mani and weld a KA flange to it?

Tyler

Y do that when you can build your own?

[Lucient]

Keep us updated... u might be able to mass produce


Oh no. I see why they charge so much for these things. It takes a lot of time to cut everything and make sure it fits, then bevel the edges of each joint, tack it together, take it apart and weld it up, machine all the surfaces flat and still hope it fits. Im sure full race only makes about $200 on each one they make.

[k0013]

thats ultra bangerang man nice work

[hellfire]

Y do that when you can build your own?

Easier.

Tyler

[Blake]

nice work
looks good:goodjob:

[Cameron.]

nice work i saw this on zilvia too.

[2isbetterthan4]

looks good, keep us updated on the progress. I would also weld some support stingers from the runners to the flange to keep things straight when that thing heats up.

[icantdrift]

Why didn't you just cut the flange off an SR mani and weld a KA flange to it?

Tyler


most of the cheapo topmount manifolds have pretty crappy turbo placement IMO, if i were doing a KA-T i'd go the same route as the guy posting the thread. also, the schedule 40 piping is much more resistant to cracking than the thin cheap stainless used by the chinese brands. plus it's a fun project for someone who likes fab work.

[hellfire]

I never said he had to use a cheap mani though.

Tyler

[Lucient]

I never said he had to use a cheap mani though.

Tyler


Also I think the chinese manifolds are stainless steel and I dont have a TIG welder to weld to stainless. Most of the chinese made top mount manifolds have great flanges but the thickness of the tubing can not support the turbo when things heat up and thus they crack. Also the turbo placement is less than ideal since it almost hits the brake lines and master cylinder.

[hellfire]

Ahhh! I never said use a cheap SR mani. LoL..

Tyler

[Batlground Motorsports]

Nice work man, Brandon (our tech) just got his flange in and he is about to start his top mount manifold. He is going to do the first one out of Mild, until me make sure that we are happy with it, after that we should have a nice manifold to Jig off of.

Good luck with your project it looks good. The Merge actually looks awesome thats where most people really screw it up.

Matt

[Koukidrftr]

I never said he had to use a cheap mani though.

Tyler

He can brag about building his manifold instead of just buying one. You know kind of like instead of buying a car already fixed up. you do everything yourself.

[v-empire]

woo woo.. seems fun!

i once upon a time used to enjoy doing this too...

now i just buy it..:(

me = lazy lazy...

keep it up, mang!

[de3zy]

where do you work? cant wait for the finished product. all these peices you can buy at most metal shops?

[hellfire]

He can brag about building his manifold instead of just buying one. You know kind of like instead of buying a car already fixed up. you do everything yourself.

I know. I was just saying.. It would be easier. But more power to him!

PS. Your car going to be ready anytime soon?

Tyler

[Koukidrftr]

I know. I was just saying.. It would be easier. But more power to him!

PS. Your car going to be ready anytime soon?

Tyler

i wish! roll cage is going to be this month or next. i ordered the digital dash this week so im close but still need paint

[Lucient]

I finished tacking together the last runner today and now Im about to take it apart and clean every joint before final welding. Any tips from anyone who has done this before would be greatly appreciated. One thing Im afraid of is the metal warping and not fitting back together

http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02046.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02047.jpg

[tacos14]

sick

[babowc]

Looks greeeeeat!

[Blake]

looks really nice
:goodjob:

[ThatS13Guy]

thats nifty!!

[2isbetterthan4]

just alternate sides. Bolt it too something if you can. otherwise run a bead, then go to the other side of the manifold and run antoher one, and so on and so forth. Thats what i am doing with Dominics Intake manifold right now. should have it done by the end of the week. Looks good though. Should spool quick with short runners like that.

kyle

[icantdrift]

Ahhh! I never said use a cheap SR mani. LoL..

Tyler


well in that case who wants to cut up an expensive manifold? lol. he's building a good solid manifold that's very unlikely to break and is still cheap to own/make.

[babowc]

What's the progress on this?!

[MOOREOFSTEPHEN]

What's the progress on this?!

800whp

[dhumps]

and a cookie

[Memme]

800whp?! That's it?!

TEH LAME... :toung2:

815whp FTW! :goodjob:

[babowc]

I want to see how a this mani turned out since it's been MIG'd versus TIG..
.. where is this guy at? :(

[de3zy]

x's 2

[I RON DON KEY]

He's posting more porn on IA.

[pitcha-Fit]

looks good