How it's Made, SR20 Turbo Manifold
A SR20 turbo manifold documented from start to finish. This is a 4 into 1 design made from schedule 40 304L stainless steel w/ 1/2 in. thick mild steel flanges. This particular mani was made for a T3 flanged turbo and a TiAL 44mm wastegate.
SR20 Turbo Manifold Fabrication, Part 1 | TurboFX
Determine the collector dimensions, build a saw/mill/rotary machining fixture, and start cutting.
SR20 Turbo Manifold Fabrication, Part 2 | TurboFX
The collector pieces have been cut, now it's time to prep them for assembly. First they are de-burred, then the stainless is brushed/cleaned, and finally tacked together.
SR20 Turbo Manifold Fabrication, Part 3 | TurboFX
The collector is fit to the turbine flange and tacked on. The runner material stash is raided and the puzzle pieced together...look a manifold! At the end of this process, all the runners have been tacked, prepped, and are ready to weld.
SR20 Turbo Manifold Fabrication, Part 4 | TurboFX
TIG welding time! A Miller Dynasty 200DX inverter was used to weld this manifold together. Start with the collector or the runners, it really doesn't matter. Also, all components are back purged. Here's the collector.
SR20 Manifold Fabrication, Part 5 | TurboFX
More welding, here are the runners.
SR20 Manifold Fabrication, Part 6 | TurboFX
So the runners are welded to the head and turbine flange. Next step is determining where the wastegate will be placed on the manifold. A jig/fixture could be used for this step. In this instance though, the car was used to figure out placement. Measure twice, cut once, and add the wg port to manifold.
SR20 Manifold Fabrication, Part 7 | TurboFX
Almost done! The manifold is fully welded and needs a little TLC before it's ready for service. First up, all flanges are machined flat ensuring a leak free seal.
SR20 Manifold Fabrication, Part 8 | TurboFX
Flat flanges, check. Usually last, the most tedious part of the build is the port job. With a 110V single stage oilless air compressor, this can take a while! Carbide bits are first used to profile the flange transitions. Then lower grit sanding drums are sent in to reduce carbide bit grinding marks. Finally the grit of sanding drums is stepped up until the transitions are smooth.
All done and good to go!
SR20 Turbo Manifold Fabrication, Part 1 | TurboFX
Determine the collector dimensions, build a saw/mill/rotary machining fixture, and start cutting.
SR20 Turbo Manifold Fabrication, Part 2 | TurboFX
The collector pieces have been cut, now it's time to prep them for assembly. First they are de-burred, then the stainless is brushed/cleaned, and finally tacked together.
SR20 Turbo Manifold Fabrication, Part 3 | TurboFX
The collector is fit to the turbine flange and tacked on. The runner material stash is raided and the puzzle pieced together...look a manifold! At the end of this process, all the runners have been tacked, prepped, and are ready to weld.
SR20 Turbo Manifold Fabrication, Part 4 | TurboFX
TIG welding time! A Miller Dynasty 200DX inverter was used to weld this manifold together. Start with the collector or the runners, it really doesn't matter. Also, all components are back purged. Here's the collector.
SR20 Manifold Fabrication, Part 5 | TurboFX
More welding, here are the runners.
SR20 Manifold Fabrication, Part 6 | TurboFX
So the runners are welded to the head and turbine flange. Next step is determining where the wastegate will be placed on the manifold. A jig/fixture could be used for this step. In this instance though, the car was used to figure out placement. Measure twice, cut once, and add the wg port to manifold.
SR20 Manifold Fabrication, Part 7 | TurboFX
Almost done! The manifold is fully welded and needs a little TLC before it's ready for service. First up, all flanges are machined flat ensuring a leak free seal.
SR20 Manifold Fabrication, Part 8 | TurboFX
Flat flanges, check. Usually last, the most tedious part of the build is the port job. With a 110V single stage oilless air compressor, this can take a while! Carbide bits are first used to profile the flange transitions. Then lower grit sanding drums are sent in to reduce carbide bit grinding marks. Finally the grit of sanding drums is stepped up until the transitions are smooth.
All done and good to go!
Last edited by javierb14
on 2011-03-31
at 03-05-16.
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Originally Posted by FuLLah 
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