Did my uppipe this morning

That spinning thing that makes all of the cool noises. OE and Aftermarket.

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douglas vincent
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Did my uppipe this morning

Post by douglas vincent »

Did this this morning.... Made the uppipe.

Parts......

Image

Used an existing manifold flange and pipe, welding it to the extra intercooler pipe I had

Image

Image

The turbo flange is 2.75 opening and I had to get there from a 2" pipe, so I bought two reducers and welding them in and up!

Image

And the finished product.

Image


Cost me $10 for the two reducers and the flange.

Next is the downpipe and 3" exhaust. I am probably going external wastegate, if the Audi 5000 wastegate I got an EBAY is any good.
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Post by livestrong14 »

great work man! +1,000 for inexpensive parts!

You need to stop by our shop sometime!
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Post by Kelly »

You water test those welds? :shock:
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Post by thehookeup »

i love the welds buddy, they look AWESOME. do you sense my sarcasim? haha jk
-93 2.2T (RIP), 93 N/A best car on earth.
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Post by 206er »

couple things about the welds-
turn up the heat for the inside 90's on the flanges, down a little for the butt welds. the heat for the weld connecting the two reducer pieces looks about perfect. some of the others I gaurantee you will crack, probably pretty quickly.
let a puddle form before you start moving
what wire setup are you using? some welds look like the wire is sticking a little bit or something.
if its flux core you ought to take some time to really learn how to use the stuff, its much harder than solid wire and gas.

you going turbo now?
Last edited by 206er on Sun Jan 28, 2007 4:26 am, edited 2 times in total.
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douglas vincent
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Post by douglas vincent »

Finished the downpipe..... Its just 2.5" for now, didnt have any 3"

Image
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
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Post by douglas vincent »

thehookeup wrote:i love the welds buddy, they look AWESOME. do you sense my sarcasim? haha jk

Ummmmmmmmmm, and you're talking? :-D
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
douglas vincent
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Post by douglas vincent »

If I could weld aluminium, and had the oil line, the damn thing would have started tonight!
>:D

Image

Image

Notice how the turbo out goes so nicely into the supercharger! :)

Also notice how restricted my inlet to the turbo is :(

I plan on making a weird box thing with flat filter for the air box.....
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
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Post by stipro »

I like it, your crazy, but I like it. Your a real enthusiest!! :-D
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Post by douglas vincent »

206er wrote:couple things about the welds-
turn up the heat for the inside 90's on the flanges, down a little for the butt welds. the heat for the weld connecting the two reducer pieces looks about perfect. some of the others I gaurantee you will crack, probably pretty quickly.
let a puddle form before you start moving
what wire setup are you using? some welds look like the wire is sticking a little bit or something.
if its flux core you ought to take some time to really learn how to use the stuff, its much harder than solid wire and gas.

you going turbo now?

I am using .030 wire, CO2....

I am getting better. :?

on the inside of the turbo flange, I also welded the inside and ground it down, that should help alot....
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
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Post by scuzzy »

douglas vincent wrote:
206er wrote:couple things about the welds-
turn up the heat for the inside 90's on the flanges, down a little for the butt welds. the heat for the weld connecting the two reducer pieces looks about perfect. some of the others I gaurantee you will crack, probably pretty quickly.
let a puddle form before you start moving
what wire setup are you using? some welds look like the wire is sticking a little bit or something.
if its flux core you ought to take some time to really learn how to use the stuff, its much harder than solid wire and gas.

you going turbo now?

I am using .030 wire, CO2....

I am getting better. :?

on the inside of the turbo flange, I also welded the inside and ground it down, that should help alot....
Not that I'm ragging on you, but do a lot more test welding on scrap before welding a finished product that you're going to put into use - otherwise it's not going to last long.


Using pure CO2 gas, while that works, is encouraging oxide formation and will eventually trash the welds - sooner rather than later; get CO2 and Argon mix, like 80% Argon and 20% CO2

a little more expensive, but you won't get near as much splatter, the arc will be easier to control

I've also heard that a mix of 70% Argon, 28% CO2 and 2% O2 is starting to become more popular for welding steel, but I haven't used this combination myself.

Anyway, it looks like the pure CO2 is making your arc hard to control, dump it in favor of a mix and you'll have an easier time getting better :)
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Post by 555BCTurbo »

scuzzy wrote:



Not that I'm ragging on you, but do a lot more test welding on scrap before welding a finished product that you're going to put into use - otherwise it's not going to last long.


Using pure CO2 gas, while that works, is encouraging oxide formation and will eventually trash the welds - sooner rather than later; get CO2 and Argon mix, like 80% Argon and 20% CO2

a little more expensive, but you won't get near as much splatter, the arc will be easier to control

I've also heard that a mix of 70% Argon, 28% CO2 and 2% O2 is starting to become more popular for welding steel, but I haven't used this combination myself.

Anyway, it looks like the pure CO2 is making your arc hard to control, dump it in favor of a mix and you'll have an easier time getting better :)
A lot of that is not accurate...

Running pure CO2 is not really a problem, apart from it just makes it more difficult to weld...as the bead is more likely to be contaminated... Your welds don't look too bad for a beginner, or for doing it on round stuff (total PITA!)

On your next bottle fill, I would suggest running 75/25 (75% argon and 25% C02)...That is what I use and the welds turn out really nice. (plus I have been welding for a few years lol)

Scuzzy, the gas you were alluding to is AB trimix...but it is a mix of Argon, Co2, and Nitrogen...and is used for welding stainless, which requires a hotter arc...so I wouldn't recommend its use on mild steel

Keep on truckin' Doug!!
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Post by douglas vincent »

All of the pipe has been stainless.
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
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Post by scuzzy »

555BCTurbo wrote:
scuzzy wrote:



Not that I'm ragging on you, but do a lot more test welding on scrap before welding a finished product that you're going to put into use - otherwise it's not going to last long.


Using pure CO2 gas, while that works, is encouraging oxide formation and will eventually trash the welds - sooner rather than later; get CO2 and Argon mix, like 80% Argon and 20% CO2

a little more expensive, but you won't get near as much splatter, the arc will be easier to control

I've also heard that a mix of 70% Argon, 28% CO2 and 2% O2 is starting to become more popular for welding steel, but I haven't used this combination myself.

Anyway, it looks like the pure CO2 is making your arc hard to control, dump it in favor of a mix and you'll have an easier time getting better :)
A lot of that is not accurate...

Running pure CO2 is not really a problem, apart from it just makes it more difficult to weld...as the bead is more likely to be contaminated... Your welds don't look too bad for a beginner, or for doing it on round stuff (total PITA!)

On your next bottle fill, I would suggest running 75/25 (75% argon and 25% C02)...That is what I use and the welds turn out really nice. (plus I have been welding for a few years lol)

Scuzzy, the gas you were alluding to is AB trimix...but it is a mix of Argon, Co2, and Nitrogen...and is used for welding stainless, which requires a hotter arc...so I wouldn't recommend its use on mild steel

Keep on truckin' Doug!!
Just speaking what I know and have been taught, 555; and I thought he was using stainless, hence an argon mix would make it easier to weld.
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Post by Kelly »

Stainless is always tuff to weld hot enough, why I usually use mild for pipe sets. Dougs welder actually works pretty damn well. I used it to peice together some stainless last week, and ya, the CO2 is going away as soon as the bottle is empty. Its just kind of hard to waste what you already got especially when on a budget.

I've never had good luck with the trimix either. Sure its hot, but it really sucks just blowin through everything you touch with it.

Id just water test it, and if it cracks, fuggit. Just reach back up there and fix it when it does. :-D

Doug, I love ya man. You are an excellent friend and an inspiration to me. Cant wait to see that thing beat modded STI's.
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Post by 206er »

Ive heard(and there is a lot of hearsay when it comes to welding technique and specs) that pure argon is the way to go for SS.
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Post by douglas vincent »

Here I am welding.

Image
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
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Post by gto7419 »

hehehe, that is an awesome picture... :-D
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Post by douglas vincent »

I found an AWESOME FREE stainless bar for building brackets....

They are called knives!

Just get some stainless knives for free from the kitchen and weld them up!

Or go to Goodwill and get some for $0.25 each.....

I welded up a stainless butter knive to a stainless tube. Damn strong weld...
Reddevil, Awaiting new heart, will it ever happen?
1990 wagon, EJ25 12.3 @ 116.5 FAST Family wagon getting new motor soon
1992 wagon, wifes daily, high compression
1992 Touring wagon, should I keep it?
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Post by gto7419 »

douglas vincent wrote: Just get some stainless knives for free from the kitchen and weld them up!

Are you really married????? :shock:
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Post by thehookeup »

doug im suprised she didnt kill you, or does she know. by the way awesome pic of you welding hahahahaha
-93 2.2T (RIP), 93 N/A best car on earth.
-00 legGT, 18" PIAA sport mesh wheels, front/rear Rallitek sways, lowered whitelines, coming soon: 2.5L sti internals, 20g heads P&P, twin charged. motor is almost ready to go in.
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Post by jake15 »

she didn't have any way to kill him.... he welded all the knives to his car :lol:
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Post by thehookeup »

jake15 wrote:she didn't have any way to kill him.... he welded all the knives to his car :lol:

i dont know why but i think that is quote of the year. hahaha
-93 2.2T (RIP), 93 N/A best car on earth.
-00 legGT, 18" PIAA sport mesh wheels, front/rear Rallitek sways, lowered whitelines, coming soon: 2.5L sti internals, 20g heads P&P, twin charged. motor is almost ready to go in.
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Post by Kelly »

douglas vincent wrote:
Image
And this pic of Dougs children are my new desktop. :-D
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Post by AWD_addict »

Butter knife brackets are an awesome innovation.
Kelly wrote:And this pic of Dougs children are my new desktop.
You and your box of kittens in the van. :lol:
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