Thread: Top Mount Manifold Build

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  1. #1 Top Mount Manifold Build 
    Join Date
    Feb 2007
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    142
    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.




    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




    Here is a jug I made to cut the top flat




    Then I tacked on the turbo flange. I was told to put bolts in the flange when welding it so the holes dont warp.




    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.




    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
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  2. #2  
    Join Date
    Apr 2008
    Location
    Atlanta
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    nice!
    06 Laguna Blue - Turbo & Nitrous
    04 Grand Prix White - 2.5L Stroker & Nitrous
    00 Grand Prix White - Supercharged
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  3. #3  
    Join Date
    Feb 2008
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    1,286
    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
    DIY... bc im made of time, not money
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  4. #4  
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    Jan 2007
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    nice.
    I've seen ya posting on KA-T.org and you're making really good progress!
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  5. #5  
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    good stuff man
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  6. #6  
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    May 2007
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    Lima, Ohio
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    bad ass looks like a good start...

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

    Quote Originally Posted by BH
    Drifting isn't racing.... it's just a way to waste everything you could possibly have.
    Quote Originally Posted by foreverbrokeride
    Your penis should be able to file for emancipation/divorce if you wouldn't poke that... that's criminal neglect...
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  7. #7  
    hellfire's Avatar
    hellfire is offline Killswitch Performance I made you a kouki but I eated it
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    Why didn't you just cut the flange off an SR mani and weld a KA flange to it?

    Tyler
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  8. #8  
    Join Date
    May 2007
    Location
    Lima, Ohio
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    daam never thought about that before

    Quote Originally Posted by BH
    Drifting isn't racing.... it's just a way to waste everything you could possibly have.
    Quote Originally Posted by foreverbrokeride
    Your penis should be able to file for emancipation/divorce if you wouldn't poke that... that's criminal neglect...
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  9. #9  
    Zippy69's Avatar
    Zippy69 is offline vroom....whoosh!!! Men with guts attack those corners...
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    Nov 2007
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    Nicholson
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    Nice job. Looks like it will be a well built manni.
    It's not how fast you go, it's how fast you go fast!!!


    Everybody wants to party like a ROCKSTAR...
    I'd be happy just to mingle like a cover band.

    http://240atlanta.com/forums/showthread.php?t=18726

    ^^^^^^^^^^^^
    Mah fo sale thread!!!

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  10. #10  
    Join Date
    Jan 2007
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    Quote Originally Posted by hellfire View Post
    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?


    Team Stick&Slide #003
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