2.9 Twin turbo project - Making manifolds

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Capri_Andy
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2.9 Twin turbo project - Making manifolds

Post by Capri_Andy »

This is a long term project of mine, well actually it was just an expensive collection of parts until now but I've been doing the R&D for years. Things are starting to happen now that I'm making the turbo manifolds for my college engineering project and get to use the college machine shop for it.

I bought the turbos and intercoolers a few years ago. The brand new Borgwarner K16 turbos were a bargain, £150 badly listed on ebay as Bentley Continental turbos. They have VW/Audi part numbers but they dont match anything on the internet, the closest match is audi RS6. The twin intercoolers match the core size and shape of the 2.8 radiator so will fit neatly behind the grill.
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Just trying it on for size...
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The original plan was to build some basic log style manifolds and use xr4x4 Turbo Technics parts to handle the fuel and ignition, with a standard compression ratio the engine would be safe in the region of 225bhp. I bought the turbo technics parts which included the throttle body with 7th & 8th injectors which are controlled by a stand alone DCU.
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This was the basic kind of turbo manifold I was going to build using stainless steel weld fittings.
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Then the project evolved before it even started. I sold the 1980s TT stuff and I bought a Megasquirt ECU which would be a lot more reliable and tuneable than TT stuff. Also I found some low compression Turbo Technics cylinder heads on ebay and snapped those up so the engine will be less prone to detonation, blowing holes in the pistons. Now I had upped the game, with compression ratio and fuelling for over 300bhp with a set of saab aero fuel injectors, things got serious on the turbo manifold front...

The best manifold design for the most power with the least turbo lag is a tubular manifold with equal length runners and a proper 3 into 1 merge collector. I did a lot of sketchs on paper of different designs until I found something that worked and put it into a Solidworks CAD drawing.
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The drawing is based on measurements I took from the cylinder head and the pipe specifications so this proves that it's possible to build in real life and provides me with the angles and lengths for every pipe that I need to cut.
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And this is what I have so far...
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For 2 manifolds it needs 1 meter of straight pipe and 12 90degree elbows which need cutting down to specific angles.

I machined the pipes for the collectors on the college milling machine.
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This is how they fit together inside.
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More soon.
Last edited by Capri_Andy on Sat Jun 02, 2012 8:47 pm, edited 1 time in total.
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The big fast red one!
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Ghia15
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Re: 2.9 Twin turbo project - Making manifolds

Post by Ghia15 »

Great work there Andy.

I am really looking forward to seeing this beast on the road.
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Re: 2.9 Twin turbo project - Making manifolds

Post by Peter-S »

Looks impressive, how's the rest of the car coming along?
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Re: 2.9 Twin turbo project - Making manifolds

Post by Craigorypeck »

Yeeeeessssssss! nice one, love a good engineering thread.
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Re: 2.9 Twin turbo project - Making manifolds

Post by nigecapri »

Capri_Andy wrote:I machined the pipes for the collectors on the college milling machine
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You jammy young pup
nigecapri wrote:and spent a morning hacksawing it to bits.
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Re: 2.9 Twin turbo project - Making manifolds

Post by Capri_Andy »

Thanks guys. No progress on the rest of the car, works ground to a halt again because I need to spend more time on college assignments. Here's a little more on the manifolds though...

The method for marking out for cutting pipes at angles.
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Turning down the short sections on the lathe to the correct size, also for cutting a chamfer to aid welding penetration.
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All the stock I need has been purchased. They are 316 stainless steel sch10 elbows from http://www.allstainlessltd.co.uk/
OCD much?
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Most of the pipes are done. I sellotaped it together!
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I still need to make the flanges. The plan is to use my CAD drawing to get them cut on the CNC mill.
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Re: 2.9 Twin turbo project - Making manifolds

Post by Beakster »

Fantastic work :D
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Re: 2.9 Twin turbo project - Making manifolds

Post by Craigorypeck »

Your so lucky having access to that equipment! I got a vice, hacksaw and file.. lol.
Good going so far m8. Top marks.
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Re: 2.9 Twin turbo project - Making manifolds

Post by BMWcapri »

Fantastic design and fabrication on those manifolds, can't wait to see more :)

Are you sticking with the standard CR and pistons or going to low-comp forged pistons?

How much boost are you going to run? Great project :applaud:
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