Making Turbo Exhaust Manifolds / Headers (M113k, E55 Engine)

Turbos are on! The rest of the car is still left, but will be starting work soon

[@firasalwakeel5365]

First guy I have seen once he is bored, he starts building up his own exhaust manifold.. dude you rock!!

[@jangzstarr]

I don’t often comment on KZbin channels and there are soo many channels out there, BUT; this one is special for damn sure! I've been following this channel since the first homemade car with the D-Series Civic engine and I love this channel so much. I think its super cool that you push the boundaries and do it all yourself, being creative and innovative with your ideas and it’s defiantly inspired me to do my own 'serious' project that everyone says I'm crazy…. Crazy is simply their limitation. I got my tools and TIG welder ready, keep up the amazing work man this is going to be SICK!

[@vazfx16]

Great job on this! I have made a few turbo manifolds and headers. You have done well in my eyes. Thanks for sharing.

[@Split10uk]

This channel should have a massive audience...maybe you need to buy a Lambo that had been in a fire 😉 Good work BTW :)

[@410kane]

Split10 like Tavarish

[@Mercmad]

Or burn a lambo ....

[@xdanano]

and make 20min episode on every bold on the car

[@vijayvjn6874]

this channels shames bisforbuild and the other idiots who make car for the entirely wrong reasons as pieces of artwork, hope this channel blows up soon

[@rileys8741]

So freaking cool. Love your custom fab stuff, dude!

[@yuriykarpov772]

well done! looking forward to what comes next. cheers!!

[@doit_vehicles]

who cares how it looks ! you saved a lot of $$$ by building it yourself !

[@xfmotorsports]

Well that and also no aftermarket turbo manifolds available for this engine

[@justarandomweeb3220]

If it works its not stupid

[@Mr.SlipperyX]

as always, I am blown away

[@TechSurreal]

Great content as always!

[@altink8823]

I just came across your project and I'm definitely subscribed 😁👍🏻

[@garrisonk8627]

you deserve ALL the subs. your channel is insane man. keep it up

[@1one3_Racing]

3 days ago? How did you sneak out a video without me seeing? Play! Play! Defiantly hit the play button!

[@HUBBABUBBADOOPYDOOP]

If you haven't already made the assembly final- scrub down the manifolds with acetone and wire brush, rinse thoroughly with acetone. Apply several (4) medium coats of either VHT Flame Proof Header paint or similar. Air dry 24 hours. Bake in preheated 300F (148C) oven for 2 hours, shut oven off, let cool in oven. Turn on oven again, 350F (176C) for 2 hours. Let cool inside again. The result will be a nicely flowed and hardened ceramic coating. Even if you plan to wrap the manifolds- a heavy coating will help to insulate and hold heat better than wrap alone. Also- do you have turbo blankets? Aluminum duct tape is great for plug wires and hoses- anything you want to reflect heat from. That engine should breathe way better now. BTW baking ceramic in your house oven does not ruin or make anything "poisonous", that is pure myth. Just provide adequate ventilation while the paints' acetate is gassing off in the curing process. Cheers (similar www.walmart.com/ip/Duplicolor-SP998-VHT-Flameproof-Coating-Paint-Nu-Cast-Cast-Iron-11-Oz-Can-Withstands-Temperatures-Up-To-2000-F/51034514 )

[@xfmotorsports]

Thanks for the suggestion. I did use header paint but didn't bake it. I'll keep this one in mind if mine ends up burning off

[@HUBBABUBBADOOPYDOOP]

If it was initially sprayed on heavy enough- you can cure it in situ with a propane torch or high heat gun. If it's not pre flowed before put into service, it will probably crack and peel from expansion.

[@HUBBABUBBADOOPYDOOP]

We're talking about high temperature paint- not that new fad clear coating for paint and other stuff. I have used VHT since it's first formulation. It contains ceramic powder, that bakes on. No snake oil.

[@xr500t]

I would consider adding some bracing to the turbo's. I'm thinking that the weight may cause the manifold to crack. It may not, the tubing is short and the turbo is centrally located..... just thinking out loud:)

[@xfmotorsports]

I think the manifold should be strong enough considering the down pipe won't have much weight either. If it still cracks then yeh I'll definitely make it stronger

[@morganfreeman5171]

Yes I think the weight, vibration and heat combo may cause some problems, i would defenetly put brackets on the turbo's ! BTW i love the work you're doing, you come up with great ideas and do some really cool stuff, I like your way of thinking :) Thanks for the videos, greetings from France !

[@HEKTIC458]

The 55 motor looks like a beast with the turbos hanging off it

[@sonikempire]

You need to rename the title to "My super cheap custom Mercedes race car" You have to bait more lol. Can't wait to see it run. Great work!!

[@HEKTIC458]

Keep the vids coming!

[@stevengrizzle]

good vid dude!

[@Dwarfgrinder]

You could just draw it and get it plasma/lazer/water cut , whatever your budget can take.

[@rusyaidijefri4263]

Oh lord i can't wait for this series!!!!!! Wish i can help with your project tho like seriously lmao

[@tischlerbmw21]

700 WHP baby!

[@user-my9nk5er9u]

I've seen people talk about the importance of exhaust pipe length and you just make this haha. Im looking forward for more of this :)

[@xfmotorsports]

Haha. Equal volume exhaust pipes definitely have their advantages for flow but log type are better for hotter exhaust temps and saving space. Would have been really difficult making a long tube header in that little space lol

[@fredrikandersson3885]

Basically just important on an NA for back pressure if I’ve got it right

[@wwooster4164]

@@fredrikandersson3885 Tuned length has it's place on turbo manifolds too. At the end of the day, a reasonable log manifold will make the same amount of power as a tubular mainfold, it's just a matter of packaging allowances, a log manifold will never be as responsive or efficient. I'd also take into consideration the thickness of the head flange, prepare for warping, if it hasn't already from the welding.

[@anythingbenz4005]

Call it the SK55 hahah good luck, I feel like the electronics and wiring will be a pain in the ass

[@lee-lk9md]

I need these turbo manifolds. I need some fabed up

[@1Amini]

VVVELD :D jk really awesome job man, keep posting more updates

[@eljuano28]

Fabbing a simple system of heat/airflow baffling between the engine and those intake filters may help manage intake air temperature, and improve density on the upstream side of your system. I had seen you were using the stock ECM, if I remember. This solution can make for more consistent MAF or MAP sensor readings and allow your ECM to avoid causing a blind lean condition. I live in 120° weather where those issues are not entirely uncommon even on factory cars.

[@fredrikandersson3885]

That turbo lagg will be real without the charger, have you simulated an air tunnel for the aero? Keep up the Awsome work!!’

[@xfmotorsports]

No CFD done yet but I do have plans before starting the body work. Yeh, if the lag gets too bad I'll move to smaller turbos

[@saravudhnaknukool4488]

What turbo are you using? And what is your target boot? (I am your big fan)..

[@Capz0r]

Hey. First I want to congratulate you on this project, it's awesome. What material are those tubes and the flange? Been meaning to make a similar manifold for a 4cil engine.

[@heycam6755]

I just finished watching all of your videos on the E55 and was wondering why you still have the same welder that you started with. I think things would look a lot better if you had something more serious. You can get reasonably priced welders second hand. Thanks for all the content.

[@EcuXP_Chiptuning]

you need to reduce the wire speed or increase voltage to reduce spatter on those welds ...

[@Mercmad]

A quick hint, wash the inside of the tubes with solvent ( I use spraygun wash ) because when the tubes are made they use some sort of silicone based lubricant and if you were stick to a finger into the tube it will feel greasy. That lube affects your welds ,contaminating them especially if you use argon/CO2 with Mig or Argon Tig. Clean them before using the plasma as the deposits left behind also ruin the weld quality. Another Hint, get your eyes checked. If,like me your close vision is getting bad, you can't see the weld puddle correctly through the helmet lense. I bought three different helmet$ before i found that it was my eyes that were not working. I can now see the puddle clearly with my glasses on (get photochromatic in case the helmet uses batteries to work the darkening . ) it is surprising how much the weld improves once it's properly clean and you can see everything . 😉😀

[@xfmotorsports]

Thanks for the advice! I have a lot more welding work coming up so I'll give it a try. Pretty sure my vision is fine lol, but I definitely need more practice

[@rileys8741]

Dude, please do side-exit exhausts on the E55!

[@bisforbroke4233]

Gonna scream with 1.5 foot long exhaust

[@rippp2343]

Ive been watching your videos & im INLOVE with them lololol. Im trying to m113k swap a s14 & these videos have helped alot. But i have a question, how do you know all of this? Like welding, motor assembly, etc etc??

[@ramondaniel2831]

How much would you charge to make one of these? Serious inquiry. So glad I just found this channel!

[@allwheelnissan4126]

There is a channel called "Inspire Composites" showing CAD design to CNC cut foam plugs for custom fiber bodies like your project car

[@xfmotorsports]

Just searched it, good stuff!

[@moedalgarny]

I can not wait to see the end of this build 😐

[@3021bob]

I know im probably late to the party but i would of done waste gate straight on the exhaust housing to get much beter boost control

[@Hamza-or7jm]

You are gonna have a hella of time controlling boost with that waste gate location. You should have welded waste gate flanges on the turbine. Your gonna have a lot of boost creep. Otherwise props to your build man.

[@jerry-md9pf]

you sead oil goin up the pips on cornering instead of the pump just fit a 1 way valve to each drain line so it carnt go back up the lines

[@coronapack]

You selling the supercharger set up?

[@SpeedingTube]

Awesome work dude. I cant help but think that 7mm is going to be too thin. If you could increase it to maybe 10-12mm in this early stage? For the small extra cost, you could be saving a headache down the line. The new project looks awesome! This will be a big channel in a few years. No ego or BS, just great experimental content for the petrol heads. Keep it up dude! :-)

[@xfmotorsports]

Thanks! yeh, it might be too thin but I'll give it a try first. I have a feeling it will be okay considering the factory manifolds were 8mm and held up to quiet a lot of back pressure

[@SpeedingTube]

@@xfmotorsports The factory headers are shockingly bad, I noticed a huge difference after fitting the Eurocharged mid length manifolds (I think you US chaps call them Headers). The standard log manifold back pressure would have increased the temp but turbos are a big restriction and adding boost + more fuel will get them glowing! I hope they're ok and I'm wrong bud, with a low boost application decent sized wastegate should help illuminate boost creep and get the heat away. Good luck, can't wait to see it running! There has been a boosted M113k CLS55 before and it ran 10's! Can't wait to see what numbers you do! Iro 850 I'm guessing! 😎👍

[@W210Garage]

From what material is it done? Don’t think that oe is regular metal. Otherwise great job ;)

[@xfmotorsports]

The tubes were aluminized steel from vibrant performance, turbo and wastegate flanges are stainless steel and I believe the sheet metal was mild steel

[@hondatrix]

Some questions: How do you intend to prevent reverse flow? Are you supporting the turbo on brackets?

[@xfmotorsports]

Back pressure in the exhaust is something every turbo engine will have. You just have to compensate for it in the tune by retarding the ignition timing. For turbo brackets, I might support it later with the downpipe or the frame depending on the need

[@hondatrix]

@@xfmotorsports That is true, but deigning the system to have the least possible amount of reverse flow and back pressure will free up power, efficiency and ultimately a much more responsive motor... I would brace it before any heat cycles as that 7mm flange will not last. Perhaps from the turbo exhaust housing to the block is best.

[@mfortugapt4life]

Are you using gas while welding?

[@marcocerqueira2732]

What turbos are you using? Excited about this build!

[@xfmotorsports]

They are a similar size to the Garrett GT35 but no idea what they really were. 1.06 A/R turbine. Worked amazing on the previous setup. I'll go with the gtx30 series next if the size turns out too big without the supercharger

[@d3inx251]

@@xfmotorsports great work. I will share some of my knowledge during working on turbos. I think you will need to measure and control EGT because of materials you use for manifold and turbo. Manifold heatshield is a must (stock was dual sheetmetal so much less wall temp) to protect surroundings and isolate compressor outlet as much as you can. I hope you have a water colled bearing housing. I'm also worrying about cracks on the manifolds (hope you will share the results preety soon). You are not allowing the flange to move during thermal expansion by joining the ports - it could cause a stress and cracks ;/. Your fixing holes needs to be adjusted in size because of it also (if not your bolts will be cuted). Make one very tight as a fixing hole (the closest one to the center of manifold) and the rest bigger - You can easily calculate how big the movement will be due to temperature. Just see how it is done on the stock. Check the bolts tightening from time to time :) BTW Your manifold will be much more efficient by doing a "v shape" between cylinders 2-3 (avoiding pulses from cyl1 and cyl2 going to cyl3 and cyl4 (and vice versa) insted of going to the turbo). Look at this: www.blackcatmotorsport.co.uk/shop/mazda-mx5-turbo-manifold-garrett-turbo/ I think you probably know all that things but it's better to write it :). I hope it helps you somehow :) Keep going mate and share as much as you can.

[@xdanano]

Is there enough space in the engine bay of the E55 to fit setup like this?

[@xfmotorsports]

No, definitely won't fit in an E55

[@akmalps9999]

Why not twincharge the engine? No lag and high boost ftw!

[@spooky8662]

Have you seen Mazdas 4-3-1 manifolds? Seems like they have the best design for compact headers. Seems like a pretty good little header though.

[@xfmotorsports]

Yes, but this one doesn't have the right fire pattern for that. I was thinking longer tubes before but would have been impossible considering the space

[@spooky8662]

@@xfmotorsports ah makes sense.

[@AverageNeighbor]

Awsome work so far, were you educated in this, tech school? Trade school?

[@xfmotorsports]

No, was educated in electrical. Racing is just an extreme hobby!

[@AverageNeighbor]

@@xfmotorsports awesome I'm in school now for mechanical engineering, any tips on how to stay motivated with it? Keep up the great content man

[@nickludu2251]

Your smarter than a GM engineer

[@christianrodriguez1740]

Would you make more ? I’ll buy them

[@TheAmazeer]

Clean your metal parts before soldering... You'll get better results

[@stgmaofficial]

I’m looking to do this and fabricate manifolds myself… you think it’s possible to do this on an e55? I’d be willing to cut a hole in the fender to allow the exhaust / waste gate to come out… What would I need to be able to do this on an e55? Can I email you? If so what’s your email! Thank you for your knowledge and time

[@Liveforeever]

I've noticed from your videos that your plasma cutter leaves a dirty cut, this is because of the tip that needs changing or the torch needs repair or its a chinese knockoff

[@khaldrogo9451]

What did you decide to call it? You should call it E55 Atom lol

[@xfmotorsports]

lol still deciding between a few names. I'll pick one soon

[@kdashow1023]

Сир знаете толк в извращениях 😅

[@1one3_Racing]

If you're having masculinity issues about your welds, you can run over the top with a TIG and it will melt your weld puddle and reshape it. Have you looked at rear mounting to trans? That would be cool.

[@xfmotorsports]

Yeh, a TIG welder would've been amazing for this (only if I had one). This transmission is a bit of an awkward shape to fit in the rear, but its pretty light. Around 75kg. Think the weight dist should turn out okay

[@azargelin]

What about the body I think u should focus more on aero dynamic and maybe active aero to really destroy everything out there but really nice build

[@xfmotorsports]

Yes, for sure. The active wing worked really well on the E55 so I'll try to make a better version of that. Haven't focused too much on aero yet because there's still a long way to go but will definitely try something better

[@azargelin]

SK8215 i think u well do great and have been fallowing ur channel for a long time and is my favorite channel by far

[@NOTSOSLIMJIM]

Nice excuse... lol. If the settings are wrong, stop and fix them. Dont keep welding.

[@Shamrockjason]

Blah blah blah blah......