Top Mount manifold build

[Lucient]

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.
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02037.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02038.jpg


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
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02034.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02035.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02036.jpg

Here is a jug I made to cut the top flat
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02039.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02040.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02041.jpg

Then I tacked on the turbo flange. I was told to put bolts in the flange when welding it so the holes dont warp.
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02042.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02043.jpg


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.
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02044.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02045.jpg


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

[itsnotarex]

Looks very nice! That certainly does not look easy. So you're mounting your turbocharger forward in the engine bay like a normal honda turbo kit, but you're essentially rotating it's position so that it's on top of the manifold rather than underneath?

If that's the case, how does the rest of the plumbing for the turbo work, like the downpipe and such? I'm just curious. I think this is a sweet project. I'm also interested in what kind of performance benefits you'll see from this. Good luck man!

[yungdz]

Is this for a 240? I just got rid of a top mount manifold I never used, and I have a friend that is trying to get rid of one for about $50. Both looked very similar to your build except shiny :nautjerk:

Congrats on manning up and building it yourself though.

[patrick4588]

Looks very nice! That certainly does not look easy. So you're mounting your turbocharger forward in the engine bay like a normal honda turbo kit, but you're essentially rotating it's position so that it's on top of the manifold rather than underneath?

If that's the case, how does the rest of the plumbing for the turbo work, like the downpipe and such? I'm just curious. I think this is a sweet project. I'm also interested in what kind of performance benefits you'll see from this. Good luck man!

top mounts are not new technology, companies have been making them for years.

to the op, im impressed you can do that yourself. its pretty awesome. i wish i could weld and do that kind of stuff. keep up the good work :goodjob:

[BTLFED]

1. You can post something besides porn? :eek:

2. I admire your ambition to do that. Welding is not easy. Looks good too.

[Bruce Leroy]

1. You can post something besides porn? :eek:
.



I was thinking the same thing

good work :goodjob:

[Hektik]

1. You can post something besides porn? :eek:

2. I admire your ambition to do that. Welding is not easy. Looks good too.

:stupid:
on both 1 and 2:goodjob:

[EK Hotch]

Looks good! keep us posted. Good luck with it

[Lucient]

I finished tacking together the last runner today and now Im about to take it apart and clean every joint before final welding. Any tips from anyone who has done this before would be greatly appreciated. One thing Im afraid of is the metal warping and not fitting back together

http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02046.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02047.jpg

[patrick4588]

where is the wastegate????

[Truegiant]

im gunna assume internally wastegated turbo!~

[B_Hoov]

im impressed for this being your first time! take your time, i had about a day and a half in this one and over 600$ just in materials, you will have to weld the runners one by one using one weld all the way around each joint, best of luck to you sir, what model welder are you using?

[B_Hoov]

oh, and weld the runners INSIDE the flanges ( turbo and motor )

[d16_turbo]

I finished tacking together the last runner today and now Im about to take it apart and clean every joint before final welding. Any tips from anyone who has done this before would be greatly appreciated. One thing Im afraid of is the metal warping and not fitting back together

http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02046.jpg
http://i303.photobucket.com/albums/nn131/kohancompany123/DSC02047.jpg

LAST TIME I MADE A MANIFOLD IT WARPED AND DIDNT LINE UP THE WAY I HAD IT TACKED. I WOULD SUGGEST WELDING AS MUCH AS YOU CAN BEFORE BREAKING IT DOWN TO WELD THE TIGHT SPOTS

[Lucient]

Good Idea. thanks for the advice. I think I will first weld the collector together and route my wastegate and then write up a plan on what I can weld first while its still tacked together to try and minimize warpage.

[slow_hatch]

Wow, nice so far. I welded my own log manifold for my little setup (not near as complex as your)but it did teach me a few things. Some of those spots are going to be hard to get to with a mig, but I would think it could be done with some careful planning. Make sure you mount your flanges down before you weld them, b/c they will warp(trust me I know, lol). Good luck, and props on doing it yourself :goodjob: :goodjob:

BTW how much does that fuker weight???

[Lucient]

It weighs a metric ton. Seriously its heavy. I think its close to 30 pounds

[all-mota]

It weighs a metric ton. Seriously its heavy. I think its close to 30 pounds

about as much as some of those girls asses you post up in the rld haha.

nice work man it always feels better to do something your self

[slow_hatch]

It weighs a metric ton. Seriously its heavy. I think its close to 30 pounds

Thats what I was afraid of. I've thought of welding one up, but after I did my log out of mild I figured a topmount would be a bit too hefty. You may consider doing a good amount of bracing, and upgrading your springs on that side of your car, lol. Unfornatly thats why i'd have to stick to a stainless one :(

[d16_turbo]

any updates ???

[stephenz]

nice!

[EJdm]

wow i wish i can do something like this..it would save a lot money...goodluck on the build