hybrid mini
2.0 16v Vauxhall Powered Mini

Turbo Manifold Build

Click on a thumbnail for a full size image.

 

The flange has been laser cut from 6mm steel, the bends are pre formed and made of carbon steel at 4mm thick, as turbo manifolds go, it may be quite heavy but this thickness should prevent cracking. 

The bends were initially tacked up to the flange and held together with grip pliers whilst the tacking took place. The primaries were then removed from the flange so they could be seam welded. I'm just using a 150Amp mig welder with stainless steel wire, this should hold it all together!! I Only started taking snaps whilst I was seam welding the tacked up primaries. 

 
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Turbo Manifold tacked up to the flange Equal length primaries The turbo will sit quite high, this is perfect for a mini The turbo flange when built will be easily changeable for a T34
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The turbo that i'll be using for the moment  IHI unit sourced from a Subaru Impreza P1 The intercooler that I'll be using to start, sourced from a BMW 318 Turbo Diesel Manifold and Intercooler
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1st one welded up 2nd one welded up

 

The Primaries have all been welded now and attached to the manifold flange, the head being used for test fit a scrap.  As can be seen from the pics the 2 centre primaries seem to be very close to the cam cover gasket, I'm hoping this won't be a problem once I have added a exhaust manifold gasket and heat shield to the manifold.  

I've also welded the inside of the exhaust ports, this will be "cleaned up" with a die grinder and smoothed off.

 
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flange bolted to a scrap head to stop distortion Manifold starting to take shape Primaries sit very close to the cam cover Can be seen more so here
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This will be cleaned later

 

2nd Feb 2005 - Made some progress with the manifold and got it finished off for the new turbo.  The new turbo engine has gone in and I now just need to finish off the inlet manifold and intercooler. 

I've added just the pictures below and will make further updates when I make some more progress 

 
Shot of the manifold with the new turbo Manifold from the rear The inlet is 3" !! the turbo is a T04E, good for over 400 stallions Looks a bit like a ram !!
New engine in the car with the new manifold Another Shot Front end seems to fit ok around it Mock up of the intercooler