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Old 07-24-2007, 07:16 AM   #3
sporadic
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Join Date: Sep 2004
Fan#: 12724
Location: Fairmont, WV
What I Drive: 06 Sonic Blue ZX5 SES turbo

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Day 2

Start time: ~2:30pm
End time: ~12:30am

Entire day spent on the turbo exhaust elbow and downpipe! :drugs:
Space is very tight, and I'm having to test fit many, many times.
I bet I mounted/unmounted the elbow 30 times today.
The end result isn't all that pretty, but the welds are good even though they don't look perfect.
Paint will do wonders.

Today was a great day to work on the car.
The rain kept it cool most of the day.

Issues:
I got "sunburned"! I welded in a T-shirt yesterday. That was dumb.
My left froearm is pretty red. My wife made me wear a long sleeve shirt when welding today.
I sure didn't argue. :laugh:

The angle for the exhaust elbow was a beast.
Routing around the clutch/throttle cables (I think.. I didn't actually trace them) made for an extra 90* bend. Bummer.

My huge Magnaflow muffler doesn't have as many mounting location options as I thought. Maybe not an issue.

The stainless steel pipe didn't like the same heat setting as the aluminized steel.
The stainless melts at a much lower heat, and that led to some ugly welds but they ended up ok.

The stock exhaust is one big piece after the flex pipe.
I'd have to cut it to finish the exhaust, so it's getting put off for now.


Nice suprises:
The portion of the stock IHI exhaust elbow that I welded my new elbow to wound up being far easier to weld to than I anticipated.
That portion is 1/4" cast steel.
The trick was to keep the heat directly on the thicker steel and let the pool flow down and consume the thinner metal.

I can clamp the ground of my MIG welder to the base adjuster of the vise!
The current flows very well through the vise, so no need to keep changing the position of the ground!

Next:
Still need a short section on the downpipe.
That will have a second 02 sensor bung for a wideband, and a flange to mount to the cat.
Intercooler piping.
I wanted to do the entire exhaust, but it looks like I'll put it off until the final install.. either later this month or August.
Paint. All bare metal will get painted.
Anything that gets hot will get high-temp paint, and then baked on the grill for a while to help the curing process.

PICS

Official soft drink of the sporadic turbo build:
Ironically the plastic Coke cup is my "outside" cup.
:clap:

Exhaust elbow from above.
Notice the stuff I have to route around.


This is why I had to create a whole new elbow.
The stock IHI exhaust elbow points the wrong direction for my application.


New 3" elbow vs stock 2".


3" PaceSetter flex pipe vs stock flex.
The stock flex has an inner diameter of 1.5"! :shocked:


Testing the necessary heat setting to weld the 1/4" cast steel to the 14ga aluminized steel.
I was floored I got it right the first try.
Actually, I was so shocked that I didn't believe it was an ideally strong weld the first try...
So I proceeded to take a hammer to it. Welds didn't budge. :clap:


Today's final product, the downpipe.





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2006 sonic blue zx5 GT2871r turbo.

Last edited by sporadic; 09-05-2007 at 10:59 AM.
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