Tubular Turbo Manifold

[[ion] C2]

Short video on Page 3.

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Due to this issue (http://www.aleromod.com/forums/showthread.php?t=34609), I'm upgrading to a custom tubular manifold since the turbo will be off anyway. In this change, I'm also changing to a TiAL v-band stainless steel turbine housing.. no more exhaust leaks.

New Garrett compressor wheel installed.
http://ion-productions.com/turboManifold/1.jpg

Washin dishes.. and the compressor housing. Got rid of all the scratched up VHT on it and decided to run it all natural.
http://ion-productions.com/turboManifold/2.jpg

V-band housing installed.
http://ion-productions.com/turboManifold/3.jpg

Ready to rock.
http://ion-productions.com/turboManifold/4.jpg

http://ion-productions.com/turboManifold/5.jpg



Tomorrow the stainless exhaust flange will be CNC cut, and the manifold tacked up and finalized. Hopefully downpipe and wastegate routing as well. Long day. I'll be sure to get videos too, it's going to be loud (3" open downpipe) until I get it welded up to the rest of the exhaust. I might go to the track with it open.

[zearchyo]

looks sexy as hell mang.

[xXManwhoreXx]

Sweet dude equal length? I wanna see some sexy bends.

It Should really help your high end, log manifolds are great down low but the tubular is going to open a whole new door for you. I assume your going to retune since when you make boost will vary from you previous tune?

[cavaliers60]

you should add a g-force chip... I hear it adds 50 HP! :lol:

[[ion] C2]

Yeah it's gonna look pretty sweet when it's done.

Yesterday all we got done was the flange, collector, and removing the existing wastegate tube and downpipe, and locating the turbo relative to the flange such that he now has a jig. Hopefully done by tomorrow...

http://ion-productions.com/turboManifold/6.jpg

http://ion-productions.com/turboManifold/7.jpg

Don't worry, I'll use a fancy camera to take the final pictures.

[zearchyo]

you should add a g-force chip... I hear it adds 50 HP! :lol:

damm

[[ion] C2]

http://ion-productions.com/turboManifold/8.jpg

http://ion-productions.com/turboManifold/9.jpg

[Papa Rad17]

you should add a g-force chip... I hear it adds 50 HP! :lol:

^ I cant even describe how hard I'm laughing right now.
Ion- I still just want a ride someday. Looking freaking sweet so far, as if it didn't before. Can't wait to see some final pics and vids.... And go for a ride.

[Papa Rad17]

[QUOTE='[ion] C2;595886']http://ion-productions.com/turboManifold/8.jpg

Note, the small peice of pipe off the side is apparently not for eating. O.o
Had to.

[cavaliers60]

It's lookin' good, Chris. Loving what I see. You'll be getting a video of her once she's all done, right?

[Dobbie]

Ion, are you a freak that eats metal? :haha:

[[ion] C2]

You'll be getting a video of her once she's all done, right?
Outside drive-by videos with the 3" exhaust open.. and with it quiet.

[xXManwhoreXx]

I love me some open downpipe

[[ion] C2]

For sure being done tomorrow. So many distractions today... ffs. One runner is welded. Tomorrow the rest of the manifold will be welded, downpipe fabricated, wastegate routed, oil lines extended with metal tubing, to prevent hose cracking from being so close to the turbine like I experience all the time, etc.


http://ion-productions.com/turboManifold/10.jpg

http://ion-productions.com/turboManifold/11.jpg

http://ion-productions.com/turboManifold/12.jpg

[zearchyo]

thats a beauty! was up with the hooty? is it that cold already in MI

[[ion] C2]

he wears the hoodie for welding

[cherrington17]

http://ion-productions.com/turboManifold/11.jpg

THAT.... is a work of art....

[[ion] C2]

Manifold done.
http://ion-productions.com/turboManifold/13.jpg

http://ion-productions.com/turboManifold/14.jpg

http://ion-productions.com/turboManifold/15.jpg

http://ion-productions.com/turboManifold/16.jpg

http://ion-productions.com/turboManifold/17.jpg

http://ion-productions.com/turboManifold/18.jpg

http://ion-productions.com/turboManifold/19.jpg

Cutting the downpipe.
http://ion-productions.com/turboManifold/20.jpg

Need to have a super tight pie cut to navigate around the turbo and fuel/coolant lines.
http://ion-productions.com/turboManifold/21.jpg

Prepping it for the TiAL v-band flange.
http://ion-productions.com/turboManifold/22.jpg

[Gr1m]

damn dude thats a pretty sexy manifold. good for you.

[[ion] C2]

Should be routing the wastegate, updating oil lines, and O2 sensors today so I can finally drive it.

[cherrington17]

C2;596107']Should be routing the wastegate, updating oil lines, and O2 sensors today so I can finally drive it.

so... when are you gonna make time to fix those wires and put in a fused distro block? (so your car doesn't set on fire)

[[ion] C2]

so... when are you gonna make time to fix those wires and put in a fused distro block? (so your car doesn't set on fire)
:whistle:

[Philbar71]

Might be a stupid question... But is this your daily driver? Or do you have another car to drive around while working on the Alero?

[heineck]

C2;596109']:whistle:

:lol:

[[ion] C2]

Might be a stupid question... But is this your daily driver? Or do you have another car to drive around while working on the Alero?
It's my daily driver. I've been getting a ride to work and to the shop.


Manifold is done (including wastegate implementation), custom oil drain line is done.. all that's left is to put in the O2 bungs and install them, and shorten the charge pipe since the turbo is now more on the passenger side.

Will be done tomorrow morning for sure.. More pictures when I get back home (posting from shop).

[Redog]

Looks great man!!


you should add a g-force chip... I hear it adds 50 HP! :lol:

damm

^ I cant even describe how hard I'm laughing right now.


You guys should totally not laugh. Like, that G chip, like, totally adds about 200 HP* to any Honduh on the road (*requires use of stickers) It does suck that is only adds 50HP, to American cars :awesome:

[03Sleepr]

You guys should totally not laugh. Like, that G chip, like, totally adds about 200 HP* to any Honduh on the road (*requires use of stickers) It does suck that is only adds 50HP, to American cars :awesome:
psh only 50? I know one guy who got 80hp and almost 20lbs/ft and he only needed 1 sticker!
and the Manifold looks awesome..I want!

[[ion] C2]

Determining angle of downpipe and marking location for wastegate flange.
http://ion-productions.com/turboManifold/23.JPG

http://ion-productions.com/turboManifold/24.JPG

http://ion-productions.com/turboManifold/25.JPG

http://ion-productions.com/turboManifold/26.JPG

http://ion-productions.com/turboManifold/27.JPG

http://ion-productions.com/turboManifold/28.JPG

http://ion-productions.com/turboManifold/29.JPG

[hok666]

http://ion-productions.com/turboManifold/11.jpg

THAT.... is a work of art....





Life and Matter imitate art.

Anyway.. Ion who's shop is that? and what camera are you using you always seem to get great shots!

[[ion] C2]

Nikon D80. (The crappy ones are my Droid)

Revshift (http://revshift.com/shop/index.php)'s shop.

Any interest in any polyurethane stuff for the Alero?

[hok666]

C2;596152']
Any interest in any polyurethane stuff for the Alero?


Like?

[billytheman1188]

Like?

x2

[[ion] C2]

Name something.... anything is possible..

Trans mounts, engine mounts... all we need are stock samples.

[billytheman1188]

trans mounts and sway bar bushings FTW

BTW that manifold looks pretty dang gooood! Fannncyyyyyy

[[ion] C2]

That is what I was thinking. I'll give him a trans mount soon to make one, and sway bar bushings are a good idea.

[JLw7123]

wow looks awesome. are u going to have an external wastegate.

[[ion] C2]

wow looks awesome. are u going to have an external wastegate.

Look at the pictures..

[xXManwhoreXx]

C2;596140']
http://ion-productions.com/turboManifold/29.JPG

wow looks awesome. are u going to have an external wastegate.

Big blue thing is a wastegate...

[hok666]

trans mounts and sway bar bushings FTW

BTW that manifold looks pretty dang gooood! Fannncyyyyyy


what he said.. FTW

Also, does the 2.4 share the same tranny mount style?

[Papa Rad17]

DAMN! thats some work to be proud of. Im lovin it!

[billytheman1188]

C2;596160']That is what I was thinking. I'll give him a trans mount soon to make one, and sway bar bushings are a good idea.

DEF... i am down for those....and any other suspension components besides the control arms cause i already have bushings for them. If you need some money for a junkyard part or to buy a used one let me know so we can get some parts made for it and u dont have to have ur car off the road.

[[ion] C2]

It's LOUD. Videos to come tomorrow (low qual video this evening, though). I got 3 hours of sleep and am at work.

You can hear the turbo coastdown... my favorite.. but it's OBNOXIOUSLY loud. Every car alarm.

The one thing I noticed too was IT SPOOLS INSANELY FAST.

[billytheman1188]

Nice!!! Cant wait for the videos!!!

[03Sleepr]

Can't wait to hear it...and I'm down for some bushings too

[[ion] C2]

This thing rips.

IT SPOOLS TO 20 PSI UNDER 2500 RPM.. WTF! I can barely touch the throttle and I'm peaking boost, it's fucking awesome!

But, my exhaust fell down lol. Plastic cable ties apparently won't hold it up. The welding wire still held, but it's in front of the flexpipe so the middle part of my exhaust is dragging haha. I'll have to use some metal wire to tie it up before I leave work.

But fuck, guys, I love this. Manwhore will love the open sound. Sounds like a racecar at the drag strip when I start it.. a nd when the wastegate opens, the car just fucking sounds insane.

[xXManwhoreXx]

Boner acheived..

+1 for taking my advice on doing a tubular mani

2500? When were you hitting boost with the old setup. I was thinking with.the tubular mani you would make boost round 3500 with serious high end flow

[AleroB888]

C2;596243']But eff, guys, I love this. Manwhore will love the open sound. Sounds like a racecar at the drag strip when I start it.. a nd when the wastegate opens, the car just effing sounds insane.

Well done.

If you're running an open downpipe, it IS a racecar ;)

Watch out for false KR triggered by the noise, could yank all the timing out from under it. Pack some Permagum around the knock sensor if you get it.

[lonnie]

Damn...good job!

[[ion] C2]

Watch out for false KR triggered by the noise, could yank all the timing out from under it. Pack some Permagum around the knock sensor if you get it.
Indeed. There's a LOT of vibration right now, lol.

2500? When were you hitting boost with the old setup.
4400 RPM. Lots of delay off the line then once it hit 4400 it was just like instant ramp up to peak.

Now it's crazy. Pulls hard. Tune is wayyyy off though, hoping to fix this week.

[zearchyo]

sounds awesome

[[ion] C2]

My phone maxes out at 140dB so the exhaust note is retarded but you can hear the spool coastdown...

ZIQ1EIqsM44

[AleroB888]

C2;596299']My phone maxes out at 140dB so the exhaust note is retarded but you can hear the spool coastdown...

ZIQ1EIqsM44

You mean the WEEEEEEEEEEEooooooooooooooooooooohhhhh?

yeah, that sounds cool :p

[xXManwhoreXx]

Shit sounds good man!

Im glad it preforms better as well

[colonel6632]

amazazing!!!!!

[[ion] C2]

I took the shop guys out for a ride tonight, was hilarious. It's so much faster now. Can't wait for it to be tuned. I break traction so easily.. they were like "Yeah, I don't think you'll be running 13s anymore lol"

We tried racing one of the new mustangs and when we took off I just spun forever and I just blazed up to him and then he didn't want to race anymore lol..


By the way, I have an AEM Dryflow air filter now... no more sucking stuff into the intake lol.


http://ion-productions.com/turboManifold/30.jpg

http://ion-productions.com/turboManifold/31.jpg

http://ion-productions.com/turboManifold/32.jpg

[[ion] C2]

LOL! I did a fly-by video with a co-worker during lunch on this side industrial road near our building, and there was another employee walking down that road talking on the phone and I ended up scaring the shit out of her when she heard my car take off hahaha. Video to come.

[billytheman1188]

C2;596454']LOL! I did a fly-by video with a co-worker during lunch on this side industrial road near our building, and there was another employee walking down that road talking on the phone and I ended up scaring the shit out of her when she heard my car take off hahaha. Video to come.
:lol: :lol: Nice

[[ion] C2]

The exhaust is closed up and quiet though, I can only imagine what her reaction would've been if it was open downpipe.. lol

Apparently she jumped off the road thinking some crazy person was about to hit her haha

[Philbar71]

C2;596457']The exhaust is closed up and quiet though, I can only imagine what her reaction would've been if it was open downpipe.. lol

Apparently she jumped off the road thinking some crazy person was about to hit her haha

I hate people like that lol

[xXManwhoreXx]

I hate people like that lol

What would you just sit there with your dick in your hand?

[[ion] C2]

Ya she was on the phone with her back turned to me so when I opened it up the tires spun like crazy and it sounded pretty mean so she thought someone was sliding off the road or something ha

[Philbar71]

What would you just sit there with your rooster in your hand?

I would actually look first, instead of jumping to conclusions. lmao