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Thread: Cummins exhaust manifold cut to fit

  1. #1

    Default Cummins exhaust manifold cut to fit

    Cut this down to fit my 4bt cummins and tig welded with my 210ext Click image for larger version. 

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    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  2. #2
    Join Date
    Oct 2010
    Location
    Northern Virginia
    Posts
    1,323

    Default

    Just curious, how did you cut it, and did you have flush mating surfaces or did you have a gap? I've always heard that for cast iron you have to preheat and post heat carefully to avoid cracking. Same deal for you?
    DaveO
    Oxweld oxy acet gear
    IMIG 200
    PowerTIG 210 EXT... Amazing!

  3. #3

    Default

    I left a small gap chamfered both sides, cut it with a band saw and I did pre heat it and clamped it to the table till cooled to ambient temps
    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  4. #4

    Default

    Very nice work. May we see the whole project ? I'm thinking about putting a 4bt in a ranger.
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

  5. #5

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    Quote Originally Posted by zoama View Post
    Very nice work. May we see the whole project ? I'm thinking about putting a 4bt in a ranger.
    Yes sir! As it unfolds:-) the 4bt will be going in a 2000 jeep tj sport all parts (minus trans adapter) will be built in house and documented. Stay tuned for more.

    also being built in house will be a long arm susension using ballistic fabrication coil over shocks
    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  6. #6

    Default

    What filler metal did you use on the exhaust manifold ?
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

  7. #7

    Default

    Quote Originally Posted by zoama View Post
    What filler metal did you use on the exhaust manifold ?
    Er70s-2 seemed to work fine, no cracking occured
    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  8. #8

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    A little more progress, reshaping the ports
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  9. #9

    Default

    Why did you choose this exhaust manifold and how much power do you plan to make ?
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

  10. #10

    Default

    Quote Originally Posted by dzljon View Post
    Er70s-2 seemed to work fine, no cracking occured
    We use it a lot without any issues. We have 316 (TIG) and 308 (MIG), but rarely use it.
    Mike R.
    Email: admineverlast@everlastwelders.com
    www.everlastgenerators.com
    www.everlastwelders.com
    877-755-9353 x203
    M-F 12 - 7PM PST
    FYI: PP50, PP80, IMIG-200, IMIG-250P, 210EXT and 255EXT.

  11. #11

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    Quote Originally Posted by zoama View Post
    Why did you choose this exhaust manifold and how much power do you plan to make ?
    I chose this manifold because I already had it and no body I know if has tried it so it made for an easy choice I am looking to get 175 hp 370 tq that should be plenty but I an going to compound this with a hx30 in the future
    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  12. Default

    Quote Originally Posted by dzljon View Post
    I chose this manifold because I already had it and no body I know if has tried it so it made for an easy choice I am looking to get 175 hp 370 tq that should be plenty but I an going to compound this with a hx30 in the future
    That amount of power should be fairly easy to get with a 4 BT. If you have an inline pump it will be very easy, with a rotary pump it will be a little harder but not much. a 3000 rpm ask a set of 4 215 injectors from a 6 BT , a larger exhaust ,an BHAF and you would be there.
    Miller 302 gas drive
    millermatic 200 mig
    miller spoolmatic 3 spool gun with 100ft ext.
    2014 Everlast PP60S plasma
    thermal arc 250 GTS inverter
    2016 Everlast 250EX
    miller tig cooler
    2015 Everlast MTS250S
    Miller 30A spool Gun
    Miller xtreme 12VS wire feeder
    Linde CM 85 shape cutter

  13. #13

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    Here is the manifold and turbo bolted in placeClick image for larger version. 

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    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

  14. #14

    Default

    The oil filter will be remote mounted
    Machines: EVERLAST Power Tig 210EXT w/ water cooler and 25' CS310 weldcraft torch
    LONGEVITY 250EX Tig
    MILLER 211 mig w/spool gun
    EVERLAST Power Plasma 80s mounted on my Torchmate 2x2 cnc table
    SMITHY 1324 mill/lathe
    60 gal. 7.5 hp air compressor


    MY YOUTUBE CHANNEL: https://www.youtube.com/user/dzljon/videos

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