New Turbo Header for my bike

Well, this project isn't really by choice, but I will need to fab a new turbo header for my bike. Did some tuning on the dyno this weekend, hoping to get up near or over the 500HP mark and got stopped short from a broken header.

Only made it to 361 rwhp before I had to stop when the turbo literally removed itself from my header. :O

It was quite hot a few times throughout testing with the load cell, although the picture below makes it look a bit hotter than it actually was (camera adjusted to the dark room and may have picked up some of the infrared from the header).

New header will consist of an investment case 304 one piece flange and head spigots and schedule 10 304 stainless weld els. I will probably weld it with 308L and 2% Lanthanated tungsten.

John

http://i120.photobucket.com/albums/o...er_Glowing.jpg

Is your sig still correct, What kind of welder didja get?

Didn't get any yet. Should have a 200DX showing up Monday (although I will likely have to reschedule and have them hold it for pick it up at the UPS hub on Tuesday, since I will be at work)

The almost 500HP is still correct as well...didn't get to push it over the 500HP mark...yet.

is that a hayabusa in your sig? kind of a tiny pic and hard to tell. so where are you gonna hide a turbo on that thing?

Yes, it is a hayabusa. It already has a turbo on it, the picture in the first post of this thread shows the turbo and the header glowing while on the dyno. The turbo is a GT35R (ceramic ball bearing) and is bigger than what most of the import car guys use... I tuned it to 484HP last year at ~ 29psi boost. This year, I was going to about 31-32psi, but only got to 18psi (i think), 361HP, and the header cracked. Header is about 4 years old and supports the full weight of the (heavy) turbo.


http://i120.photobucket.com/albums/o...der/Bike_1.jpg

i see the blow off valve and the glowing header and what might possibly be the turbine of the turbo but it's hard to tell. pretty damn close to the radiator. you don't have any heat soak issues? after i build my stroker for my jeep i'm thinking about putting a turbo on it but heat soak is a huge issue with the jeep straight six

The bike really cannot be operated at steady state condition at any real HP output.The cooling system is completely stock, and the oil cooler has been removed. The radiator will be cut down later this year for more tire clearance wen I offset the front end to allow for more swingarm length.

This bike isn't even intercooled. The intake temperatures are well over 300 degrees F. The only way it survives is that it is only under power for 8 seconds, and of that, only on full boost for about 3 seconds.

I received all of the parts to make the header; 1-1/4 schedule 10 weld Ells, length of straight schedule 10 pipe, 1/2" T3 turbine inlet flange, investment cast head flange, 308L stainless filler in 1/16th and 3/32, 2% Lanthanated tungsten in .040", 1/16", and 3/32", collets, holders, cups, gas lenses, Everlast 200 DX welder, Power cord, etc.

Just need to pick up the argon tank, design the header, and cut / fit the components and then start tacking, final fitment, cutting apart, welding, porting, tacking more, welding, porting, final welding, porting....Then finish putting the bike together and back to the Dyno to shoot for 500 HP.

John, where did you get your weld-el's from? Looking forward to seeing how your header progresses.

Quote:

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Originally Posted by jakeru

John, where did you get your weld-el's from? Looking forward to seeing how your header progresses.

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I ususlly get them from McMaster carr, but this time i got them from ACE Stainless. Reasonable cost and lots of selection
http://www.acestainless.com/butt-wel...hedule-10-304l

That thing has to be a blast. The GT35R is what us VW guys run on our VR6(15deg V6) motor. I will be running a GT3582R on one car and my other car will have 2 GT2871R's.

Quote:

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Originally Posted by Jason

That thing has to be a blast. The GT35R is what us VW guys run on our VR6(15deg V6) motor. I will be running a GT3582R on one car and my other car will have 2 GT2871R's.

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3582 on my bike as well. Ended up welding the broken header in the interest of time. Had it on the dyno yesterday with the new ECU setup and made 450hp. Seems to have a boost leak at high boost as it woudl not make more than about 27psi, even with huge amount of pressure on the backside of the wastegate (essentially keeping the gate closed). I think it may be in the connections from the throttle bodies to the head.

Header held up though....welded with an Everlast 200DX powered by a 100ft 10 gauge extension cord from my 30 amp dryer plug...No measurable heat rise on the cord and less then 1V voltage drop. :cool:

These things take very little current to run, especially compared to an old school transformer machine.

They do require very little power. My 256 pulls 22amps at 256 amps then settles down to 17 constant. for a comparable transformer you would be at twice that amperage. I love these inverters