Making a turbo manifold - Part 3 Saab B204

Part three of what I expect will be 3 or 4 part mini series.
Hope you enjoy!
Go and check out the website prorace-engine... and see what the guys have to offer.
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Energetic Intro
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[@jefflamb5343]

Just discovered your channel. Sorry I’m late to the party. LOL. First, I want to say the final design you created for your turbo manifold looks awesome to me. It’s the perfect blend of short runners in a compact space that facilitate high flow. Plus, I love the symmetry of the design. MUCH better than a log style manifold. And second, I wanted to let you know I really appreciate you taking the time to share what you have going on. You are very good at explaining things in sufficient detail and you’re good at editing to make sure your videos don’t drag on too long. And you add some bits of humor by showing the good, the bad, and the ugly as you make a few mistakes and show us what you’ve done to fix them. I know for a lot of us, it’s tough to let others see some of the mistakes, especially the ones where we look back and say to ourselves - How could I have been SUCH an idiot to make that mistake! LOL. Would be so easy to just bury that footage forever, but appreciate it that you’re humble enough to share portions of it.

[@AndyPonting]

Hi Jeff, sorry I've only just got round to responding to this. Just got to say, this is probably the best comment I've had on the channel to date. It's really nice to know that there are viewers out there that enjoy the content. It is extremely difficult (and I'm probably down playing that) to fabricate, film, present and then edit in a way that keeps enough of the info in, without losing audience interest because it drags on. I'm aware my videos are probably more detail and less "instant satisfaction" than many of the more popular channels, which is a little more niche, but that's what I enjoy watching most myself. Thank you. Really. The KZbin stuff at this level is a thankless task so your positive reaction makes it all worthwhile.

[@jefflamb5343]

Andy, I’m very glad you saw my comment. You’ve definitely earned my appreciation. I tend to break YT viewers into three main categories: 1. folks with really short attention spans with almost no ability to focus on any subject that has any depth to it, 2. folks with a sufficient ability to focus, but no interest in the type of subject matter on your channel, and 3. folks with a sufficient ability to focus and who are interested in cars, track time, and some of the technical and fabrication requirements involved with improving the performance of any given vehicle you are working on. I, along with the others in category #3, really appreciate the efforts you continue to put into your channel. It’s rare to find someone who is good at track driving, track car prep / setup, fabrication, engine building, talking / describing / presenting / hosting, video capture / editing, all with a good dose of humor thrown in. You’ve got it all !! And, I’m sure most of your other viewers and subscribers would give you the same very positive feedback if they had the time. So please know that I’m speaking for myself AND many others with my feedback. Keep up the great work!!

[@AndyPonting]

@@jefflamb5343 People will think I've paid you to say that! 😄 If I come across well on camera, perhaps I'm better at editing than I thought!

[@Daniel_D_King]

Don't be to hard on yourself bro, stainless is a big enough learning curve on its own, throw in the tight curves and awkward positions you need to get to on a manifold and it's even harder. Looks good for a first attempt mate.

[@AndyPonting]

Thanks! Yeah I know I'm hard on myself sometimes, but that's what drives me to make things as good as possible and improve.

[@Careless_is300]

always a good one when he posts im here for the volvo but everything els is sick

[@AndyPonting]

Thanks... Got to make one of these for the Volvo too!

[@BBBJBC]

Keep up the good work dude.

[@AndyPonting]

Thanks!!

[@VX220ontrack]

Well done mate keep going ❤

[@AndyPonting]

Thanks mate! Will do

[@myoniwy]

In my opinion, the turbo manifold should be as short as possible and have the smallest volume.

[@AndyPonting]

It does depend on what characteristics you're after. A log manifold is about as short as you can get and will spool up quickly, but it'll have high back pressure and will have reduced performance at the top end. There are plenty of long turbo manifolds in race cars, F1 for example, so they can work well. I could have made life easier with smaller diameter pipe but for the size of turbo I'm running 1.5" was recommended. 👍🏻

[@E36B204]

You got looooaaads of downpipe clearance 🤪 on my car i'd have the downpipe on the inside of the cabin if i'd left the turbo between cil. 2/3 😂😂 hit the like button cuz i feel your struggles 🤪😋

[@AndyPonting]

Yeah there's loads now, but just below the panel towards the bulkhead there's a rubber steering rack boot so I needed to get the dp as far from that as possible

[@mk5mark883]

Looks brilliant mate I'm currently building a sidewinder for my Mk5 fiesta with a forged st170 engine in. If my manifold comes out half as good as yours I'll be chuffed. Top work mate

[@AndyPonting]

Thanks! I'm chuffed with how it's gone overall (so far) just feel I could have done better with the welding! Oh well, there's always the next one!

[@danieljohansson1694]

Good work bro! 💪 But why a 4 inch downpipe? How much power are you planning to make? 😁

[@AndyPonting]

All of it! 😂 What size do you run? The bigger downpipe should help with spool up of the big old truck turbo!

[@danieljohansson1694]

@@AndyPonting hahah good stuff 👌 I'm running 3,5 inch and I don't have any problems pushing 850whp out of it, so I don't think you need a 4 inch plus it will be way easier to fit 😅😁

[@AndyPonting]

I'd be quite happy with 850whp 😜😜 lol, don't think I'll get anywhere near that. I've already got the 4"pipe and v bands etc and I've got the clearance now so I'll run it!

[@danieljohansson1694]

@@AndyPonting haha sounds good 👍😊

[@craigphillips4105]

Its looking great planning to try own manifold soon .. what settings did you use for your welder? Tungsten size rod size power?

[@AndyPonting]

2.4mm 2% lanth Tungsten, 1.6mm filler, 90a with pedal (~70-75a I guess when welding) with furick #12 mooseknuckle cup, #9 torch

[@craigphillips4105]

@@AndyPonting great thanks.. never welded any of that pipe yet so them settings will be a good starting point 👌

[@AndyPonting]

The pipes usually have a bevel that's only half the wall thickness. I used a flap wheel to take the Bevel to full thickness (knife edge) so you know you're getting full penetration

[@craigphillips4105]

@@AndyPonting will play about with that too on some test pieces thanks

[@matty9007]

Looks really good, Ile be well chuffed if my welds come out half as good as that. What tig welder are you using?

[@AndyPonting]

I'm using an Rtech TIG170EXT (AC/DC). I don't have any other experience with other TIG machines but this one seems to work ok!

[@devanthomas8653]

Can I buy one from you

[@AndyPonting]

Thanks, I'm honoured that you'd be willing to buy a manifold from me but at the moment I'm only doing fabrication work for myself (and the odd minor favour here and there!)