My new street car build-back thread

[jay]

So after a 2 month delay, I got started in again on making the BW 6250 turbo talk to the engine. Here's the manifold so far. 3 of the 4 runners coming off the head flange are shaped to match the oval ports and tackweled in place. Each runner is going to have to get welded section by section in order, so as to get all the way round each joint.. but I've figured out that part of it. Astonishingly, the runners are awful close to equal length, not through any real planning on my part it's just how it came out pretty much. I was just trying to get those 4 ports to talk to those 4 holes... what a PITA. It ain't gonna be perfect but it will do the job!

[bomdoutscort]

Picks of the turbo or it didn't happen!

[Iantboyd]

Glad to see some progress on this, is your buddy up here in lynden doing the welding after you cut all the pieces up?

[jay]

Naw, I'm rankin up the Millermatic and gittin r dun.

[FE3-323]

props for building the manifold yourself!!

[1st Gen]

^Agreed.

[jay]

Yah well necessity and bein broke is the mother****er of invention....

[Iantboyd]

Yah well necessity and bein broke is the mother****er of invention....

Buying an efr will do that to youl, haha. t

[jay]

By now I was hopin to post pix of the finished manifold bolted to the turbo and in the engine bay. But nooooo. Everything lined up when it was in the tack stage but when I buttoned down the turbo flange its angle changed a teeny tiny bit. Which made the turbo park in the radiators' stall. Damn. Fortunately the runners were still just tacked to the head flange. So I spent the last 3 days massaging that interface til everything fit again. so... in order to get an efr 6258 to fit in a protege, you not only get to make a new manifold, if ya wanna keep your AC, you also get to remove some material from the lower trans mounnt and bellhousing. And the turbo has to end up in exactly the right place. We're talkin plus or minus .025 in prettymuch any direction, and oh yeah I still have to swap in the vj23 wg actuator on a custom mount cuz the stock stuff won't work no way no how. And then I gotta find a pair of real small REALLY skinny radiatorfans. This project is a tiny bit stupid and I have only me to blame. GT28r ain't anywhere near as long as this BW thing.

[FE3-323]

i dispise the BG EFR design for the hotside. I much rather prefer an external wastegate with a compact dump.

I do however like the technology in the turbine wheel alloy. & the built in BOV into the comp cover(excellent idea)
but i would like to see this offered in a V band twinscroll hotside. and or a VNT system also with a Vband entry connection.

/rant
& free bump for pics~!

[Iantboyd]

Woot! Progress. Wish there were pics though. Im heavily considering the 7670. On the one hand they are spendy but on the other I have only heard great things.

Having an internal wastegate that is effective is probably one of the best advantages to these turbos. Especially since our cars dont have alot of room in the first place.

Keep at it jay. I still hope to lay eyes on these animals someday.

[Wildfire0310]

Keep up the good work. I know it's a PITA, but just remember how sweet that 6250's going to be when your done. Also I really need to learn to weld, as I bet at some point I am going to need something "custom" for the GTX.

[jay]

Well it ain't done but it's wellded. Nice where I could, boogered where I couldn't. I only had to cut one runner, once, to get the gun to a seam I otherwise could not reach. I call that a victory, at my (lack of) skill level. Lots and lots of cleanup to do yet, and a touch more portmatching to get the round pipes to talk to the oval ports, but it's coming along nicely. I think I've even figured out a surefire way to test for leaks. Gonna make a couple wood boards that bolt to each flange, tighten up with duct tape gaskets, and lower it into about 6' of nice clear water I have handy. if it bubbles, I get tio bust out the welder again. The only other thing I can think of is to put smoke in it, plug the flanges, and then have a.. what, a tire valve or something in one of my boards so I can pressurise the silly thing and see if it lets any smoke out. Am open to other ideas... once it passes that test, i think I'll sandblast it and paint it and cover it in header wrap and
finally
install
the damn thing

[FE3-323]

building a manifold is most certainly a challenge. & even more so with a mig. i give you props

[jay]

It didn't come out quite equal length. #1 is short but not by as much as it looks, there's only about an inch difference tween it and #2, and 3 and 4 are awful close to splitting the difference. I dunno if they have to be spot on for any benefit from being equal kicks in or not, but it don't hardly matter as it ain't gonna change now. I just simply ran outta real estate to get it perfect; this'll just have to do!