MR2 K-swap Project

[JamesBryan]

Welding the inside seems like a challenge to me, to say the least.

A lot of stick out on the tungsten and a decent size cup with gas lens.

 

[dann2707]

Absolutely that. That isn't an issue. It's the angles I'm not sure on

 

[dann2707]

Because I'd want a Y collector to look like this...

View attachment 1439644

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View attachment 1439646

Been looking into this a lot more now, can see that mine are at a stupid angle which is only going to throttle back the engine and with this much time and effort in I'll get something that flows better in there.

I've ordered some 15 degree mandrel bends in to hopefully learn how to do it. Total cost is £36 for 4 so if it does work it won't be expensive at all and gives me an excuse to get the tig out.

Will think of jig / fixture ideas for it to clamp it at the right angle. Shouldn't be hard at all to mock something up and print.

I now have a band saw in my possession so will use that for the sexy ass cut

 

[dann2707]

So I was borrowing my mates band saw but as its quite big it was taking up a lot of garage space. Ordered this last night for the tube cutting. Got super good reviews and it's relatively portable which is ideal. Can stack it on my shelving units now.

Last night I also designed the mandrel bends on cad that I've bought, printed them off overnight so I can have as many practise runs as I want on them.

The next step will be to receive the saw, check out the clamp area and model a jig/fixture to hold the mandrel bed at the angle I require for the merge collector.

The cost of this is racking up but at the end of it I will have a bandsaw and linisher machine for other stuff in the future.

Plus I'm getting so much f**king enjoyment out of it all which at the end of it all is what it's all about.

I'll get pics of it but I also created a cool little fixture that will hold the merge collector straight parts parellel to each other. The pipes just slide into it and are kept apart by 10mm.

 

[JamesBryan]

Can't go wrong with Starrett stuff in the engineering/measurement world, hopefully the saw is just as good.

A few tips here for bedding in a new blade to increase it's life.

 

[dann2707]

Can't go wrong with Starrett stuff in the engineering/measurement world, hopefully the saw is just as good.

A few tips here for bedding in a new blade to increase it's life.

Thanks for that mate. I'll give it a watch. Love his stuff too, his latest fab table video is one of the best fab vids I've seen on you tube.

These are the spacers I mentioned earlier. Might bring them a little closer together, 10mm looks a bit too much perhaps.

Just received my block of alu for making the purge block for the flange. So happy with jt

Will take it to work and get it machined.

And these are the 15 degree bends I printed last night to have a go on the new saw.

Finally, I made an enclosure for the 3d printer so I can now print abs, badly done as I hate plastic but still it works wonders

 

[JamesBryan]

I'd probably make the spacers at 7mm, I think 5mm might be too close so 7 should be ideal.

 

[0ss]

Dan your gonna need a unit for all your equipment soon lad. Cracking effort, I hope it works out well.

 

[Louis]

Didn't realise that band saw was so expensive when you sent me it earlier! Read it as £164 haha, that's gonna be a wicked bit of kit. Super useful too!

Getting expensive this exhaust system, but man maths

 

[dann2707]

Dan your gonna need a unit for all your equipment soon lad. Cracking effort, I hope it works out well.

I know mate it is getting out of hand. Cheers man, me too if I f**k it up I'll just pay for an exhaust and claim I made it to save face.

Didn't realise that band saw was so expensive when you sent me it earlier! Read it as £164 haha, that's gonna be a wicked bit of kit. Super useful too!

Getting expensive this exhaust system, but man maths

Haha mental innit, didn't expect to be paying that much but its something I'll use quite frequently I reckon.

It really is man mathsing the f**k out of the whole build tbh. I'm pretty bad with skills like thst though I tell myself I'll use them later in life, most likely will and its something for the cv too

 

[0ss]

You'll be knocking out manifolds and exhausts in no time. Make Louis a nice turbo manifold, the cast one's aren't worth the iron ore they came from!

 

[dann2707]

Genuinely would too if this goes to plan. Turbo manifolds look very easy compared to normal 4 2 1 headers

 

[leeds2592]

f**k me, next time I come round all I'm gonna see is a mass of 3D printers and the stuff you've made with it all over the house

 

[dann2707]

Literally 90% of Christmas presents this year are gonna be 3d printed.

 

[Louis]

Literally 90% of Christmas presents this year are gonna be 3d printed.

Flexi rex pls

 

[dann2707]

Saws been delivered next door and he's gone out how frustrating

In other news I've made the purge block for the exhaust manifold

 

[R3k1355]

Turbo manifolds look very easy compared to normal 4 2 1 headers

#loglife

 

[Coops Mk1]

Definitely, no precision needed with boost, just crank the psi to compensate

 

[dann2707]

Oh lord

Let's f**k some s**t up

 

[0ss]

Awaits severed finger post..

 

[dann2707]

It's alright I'm letting my 10 year old nephew try it out first to understand how it works, will probably learn from that how to not sever a finger

 

[0ss]

It's alright I'm letting my 10 year old nephew try it out first to understand how it works, will probably learn from that how to not sever a finger

Sounds like a good plan to me.

 

[dann2707]

Well the merge collector went rather wel ish apart from cutting one of them too close to each other but it's not the end of the world!!

Just need a vertical band saw to finish the ends off and I'm well happy

Used the 3d print to print off a fixture that holds the pipe at 12 angle for better flow

 

[dann2707]

Cut the ends off them, I just need to belt sander on them now to get them nice and straight edged.

Nice comparison between the restrictive ones I bought...

Ebay bought

Mine

Not shocking for my first go at it I don't think

I will end up going over it with the tig with more amps and back purging it at a later date.

 

[Rob G]

Loving the fab work on this dude!

 

[YorkshireKyle]

The eBay one looks like a cowboy ready to draw a gun, it just needs to have arms

And I need to stop taking so many drugs

 

[Scaramac]

Took me ages to work out what you had on your feet. Any respect for you has been lost upon realising. #shame

 

[dann2707]

Took me ages to work out what you had on your feet. Any respect for you has been lost upon realising. #shame

Do not mock, they are so versatile, comfy, waterproof, a great talking point amongst your Chinese friends, great in combat and most importantly they look amazing.

Who knew looking that great would also be so comfy?

I bought my mate a set last year for a joke and he loves them too, had them on last night before we went out

 

[leeds2592]

Took me ages to work out what you had on your feet. Any respect for you has been lost upon realising. #shame

Wash your mouth out.

I've tried them and can confirm they're stylish, comfy AND practical!

 

[Scaramac]

Wash your mouth out.

I've tried them and can confirm they're stylish, comfy AND practical!

There are no words. No doubt you people wear crocs too!!

 

[Scaramac]

great in combat

 

[dann2707]

There are no words. No doubt you people wear crocs too!!

It's really annoying having to slip off my fish flops to put on my crocs going into the garage

 

[Cookson]

Skinny fit joggers, FFS

 

[dann2707]

Go fish yer self

 

[Old Tarby!]

Fish flops LOL