paging the fabrication forum messiah

[Blue88Coupe]

Can I continue to heat and hammer this to a T4 flange size hole or will it heat cycle once the car is running and crack?

[Doug Hatton]

I can't remember where I saw it, but someone had made a vise type jig that would squeeze round tube from two directions to force it into the square shape needed to tie into a T4/T6 shape. It was adjustable to get to whatever dimensions you needed. Pretty cool little rig.

[Blue88Coupe]

I can't remember where I saw it, but someone had made a vise type jig that would squeeze round tube from two directions to force it into the square shape needed to tie into a T4/T6 shape. It was adjustable to get to whatever dimensions you needed. Pretty cool little rig.

I tried squeezing it with the vice. I should have thought of welding some pieces of iron together to cap the ends and then squeezing it. I'll try that out today. The only thing is i think the circumference of the 2.5" tube is smaller than the circumference of the T4 hole. It needs to stretch and then be shaped.

[greenbullitt]

nick, i know this isnt quite how youre doing it right now, but check this, may give you some direction

http://www.theturboforums.com/smf/index.php?topic=65147.0

[Blue88Coupe]

nick, i know this isnt quite how youre doing it right now, but check this, may give you some direction

http://www.theturboforums.com/smf/in...?topic=65147.0

My merge is done. It was interesting getting it to fit perfectly but its pretty damn close now. I checked that post and I think I used about every idea they had for squaring already. I'm about 95% fit on the flange as it sits right now. Easily enough to weld up with the mig I just dont know if its going to crack. Brooks is always talking about heat cycling parts and this seems like something that might heat cycle and crack.

Heres my merge. I cut off the curve going to the flange and im going to use a longer piece of pipe welded to my squared tube.

[Blue88Coupe]

If any of you have the under car picture of a down pipe on a drivers side mounted turbo I'd like to see it. I tried to find some pictures of boostedgt's or 93lxhorse but I didnt come up with anything.

[Blue88Coupe]

If any of you have the under car picture of a down pipe on a drivers side mounted turbo I'd like to see it. I tried to find some pictures of boostedgt's or 93lxhorse but I didnt come up with anything.

Nevermind on this. Pauls thread on the turbo board shows clearly how its run

[turbostang]

Sorry man, I just saw this thread - The easiest way I can explain for anyone to do what you are trying to do here....

First, squeeze the tubing down to the size you need it to fit INTO the flange. You will have to egg shape the shit out of it at first, but be patient.

Second - FIRMLY Tack it in place in 4 places. Say - 12, 3, 6 and 9 o'clock.

Third - Using a dull punch with about a 1/2 - 5/8 BLUNT end hammer the corners out to match the flange radii.

Fourth - Weld to your liking.

NOTE: this works best for a SINGLE tube entering the turbine flange. If you are trying to merge TWO pipes, Good luck - may the force be with you.

You won't heat-cycle crack it, but you do have a chance of a weld failing if you butt weld the tube to the flange. By putting the tubing through the flange - you can weld it inside and out.

[greenbullitt]

make sure theres no mesh liner in that flex coupler!

[Blue88Coupe]

make sure theres no mesh liner in that flex coupler!

Its just some ribbed metal inside the tube. Would it be clear to see if there was a mesh liner inside? Do you think its too small of a coupler?

[Blue88Coupe]

Well this little bit is done. I probably should have waited till school started and used their tig machine to do this but the mig didnt do too bad. I'm waiting on the mail man to bring me some cartridge rolls so I can clean it up. I image the turbo wouldnt like it if it sucked up some of those little bb's.

[greenbullitt]

a longer coupler would allow more movement, but itll be fine. If its a ribbed inner, you got a good one

[turbostang]

Your welds will improve a fair amount just by grounding the part directly instead of grounding the work table and laying the part on it.

[bigshoe]

a longer coupler would allow more movement, but itll be fine. If its a ribbed inner, you got a good one

Thats bullshit. mine has the mesh in it and its almost 5 years old with LOTS of passes and its perfect.

[Blue88Coupe]

Your welds will improve a fair amount just by grounding the part directly instead of grounding the work table and laying the part on it.

I'll do that next time. I was doing that then at school we always clamped to the table so I picked up that habit. I'm done christmas shopping, I have a few more things to buy for the turbo kit(oil in and out line, line fittings fittings, oil return flange and tube/flange for the waste gate) then im going to pick up a bottle and hose so I can get off the flux cored wire.