Bracing Heavy Turbos

Post by **DJpowerHaus** » Mon Oct 10, 2005 10:11 pm

Due to my application I cannot use any of the cast manifolds available. I need the manifold to be top mount. The eventual plan is to build a quality stainless manifold. For this I used an ebay unit that would have gone in the trash had we not decided to just throw it on and hope for the best.

So this is my situation.. top mount turbo (Holset HX35) and 35mm wastegate (Tial). The total weight for this setup is 30lbs... 30LBS! Its a VERY heavy setup. And it is mounted on a hacked/flipped/MIG'd SSA manifold. I really cant think of a worse pairing.

The wastegate comes out below the compressor housing and the weight of the WG is actually supported by an aluminum strap between its top and the housing. That much is okay at least. But I still need to support all this weight.

I'm looking for advice from fabricators and googlers for how to brace this properly. I have heard of "tripod" setups with heim joints but I have yet to actually see one of these. I know that it will need to have some ability to absorb vibrations and G loads as well as thermal expansion.

The more I learn on this "cheap" manifold the more I'll save when we make the expensive/nice one. I'll post some photos later tonight (Midnight EST) of the manifold.

Post by **DJpowerHaus** » Tue Oct 11, 2005 12:33 am

As promised...

peregrine · Post by **peregrine** » Tue Oct 11, 2005 12:51 am

maybe an adjustable rod from the turbo to a valve cover bolt?

blue1 · Post by **blue1** » Tue Oct 11, 2005 1:27 am

Adjustable rod to the valve cover bolt wont allow for to much expansion of the pipes and i dont think that little bolt will last long when the manifold does grow!

Mike · Post by **Mike** » Tue Oct 11, 2005 1:38 am

Hmm... how about some braces running from the engine mount (like stock intake manifold brace) or off the exhaust manifold studs?

Post by **DJpowerHaus** » Tue Oct 11, 2005 9:53 am

I'm thinking of a 1/8" x 1" strap from the motor mount. Still dont think it'll have enough movement though. I wnat to know what other people (and major race teams) have done in the past.

peregrine · Post by **peregrine** » Tue Oct 11, 2005 10:48 am

there probably isnt any easy cheap solution to this.

i-w · Post by **i-w** » Tue Oct 11, 2005 3:49 pm

have you seen chads setup for supporting the heavy turbo?

pm boosted one he might have a pic. i could take a pic of mine but it is in storage.

goes from the flange that mounts the turbo to the motor mount stud on the block. apiece of flat steel. about 1/4 inch by 1 1/4 inche wide flat piece of steel.

there is a stud welded to the flange on the header and the flat piece of steel has a slight bend to it.

i will see what i can do about getting pics.

i-w · Post by **i-w** » Wed Oct 12, 2005 12:56 am

i wish i could show you a pic. i just moved and everything is in storage.

it actually has a bolt welded ( for example if you are standing in front of the car the side of the header flange that is closest to the front. where the turbo bolts on to. he welded a bolt so that the threads are sticking out toward the passenger fender. parallel to the flange.) and the rest is exactly like you stated.

pm boosted one on starquestclub he might have pics.

we have the same header.

2000_turbo · Post by **2000_turbo** » Wed Oct 12, 2005 2:13 pm

That setup is cool! I've got the same setup as you, but my turbo isn't so big as yours

.

This is the manifold that i've been using. It's a DNP for the Evo I/III.

This is how we started, cutting the manifold in two pieces.

We had to extend the manifold a few cm.

Then we welded the other piece on the flange.

This is the end result. We also had to rotate the flange for the external wategate. As you can see we welded two studs between the collector and the flange.

I drove the car for three months with this setup, without any problems.

Gr,

Martijn. (The Netherlands)

peregrine · Post by **peregrine** » Wed Oct 12, 2005 4:21 pm

</div><table border='0' align='center' width='95%' cellpadding='3' cellspacing='1'><tr><td>QUOTE (2000_turbo @ Oct 12 2005, 11:13 AM)</td></tr><tr><td id='QUOTE'>

I drove the car for three months with this setup, without any problems.

Gr,

Martijn. (The Netherlands) [/quote]
i have a pic of your motor on my computer from earlier this year. werent you using a different manifold before? and if you still have it would you be willing to sell it? :rolleyes:

2000_turbo · Post by **2000_turbo** » Wed Oct 12, 2005 5:37 pm

Hi peregrine,

Yes I was using a different manifold, but I couldn't use it anymore with the new turbo. (Turbonetics T3/T04E) I have sold the manifold to a friend of mine......
Nice to "see"you again!

Gr,

Martijn.

peregrine · Post by **peregrine** » Wed Oct 12, 2005 6:18 pm

</div><table border='0' align='center' width='95%' cellpadding='3' cellspacing='1'><tr><td>QUOTE (2000_turbo @ Oct 12 2005, 02:37 PM)</td></tr><tr><td id='QUOTE'> Hi peregrine,

Yes I was using a different manifold, but I couldn't use it anymore with the new turbo. (Turbonetics T3/T04E) I have sold the manifold to a friend of mine......
Nice to "see"you again!

Gr,

Martijn. [/quote]
put up some pics of the car. it looks bad ass. what is it? an old 4 door lancer?

*edit* found it.

peregrine · Post by **peregrine** » Wed Oct 12, 2005 6:32 pm

god damn that little lancer looks sick. and just knowing whats under the hood gives me wood. how much does that thing weigh martijn?

Brent · Post by **Brent** » Fri Oct 14, 2005 2:45 am

I have some images of a large turbo that has been braced in a cleaver fashion.
How do I upload the pics?

Why dont I just e-mail them to you?

blue1 · Post by **blue1** » Sun Oct 16, 2005 7:28 am

2000 Turbo very nice manifold, thanks for some ideas you have given me! and your engine bay looks great!!

2000_turbo · Post by **2000_turbo** » Sun Oct 16, 2005 7:38 am

@blue1, you're welcome, that's what this forum is for! Thanks, I'm very proud of it!

Gr,

Martyn.

blue1 · Post by **blue1** » Sun Oct 16, 2005 7:48 am

2000 turbo if you have a spare 10 minutes would you make me a manifold: LOL well done i hope my engine bay come up like yours i will be very happy.

blue1 · Post by **blue1** » Tue Oct 18, 2005 8:52 am

Turbo 2000 is the moded part that you have done to the manifold all MIG welded?

2000_turbo · Post by **2000_turbo** » Tue Oct 18, 2005 4:39 pm

Yes, it's MIG welded.