I've been making up my exhaust manifold for the Alfa V6 this week and am quite pleased, I thought I'd share a few pics with you all.


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Just a final section to install, then fully weld, grind and polish.

Regards Dan.

Looks good Dan, thinking of building my own exhaust for the Jag V6. May I ask where you got the parts from? Especially the 3 into 1 collector, cat and silencer.

Cheers

Looking good, equel length? Stainless steel? Tig??

Pojo, Merge collectors are from CXRacing 3-1 Exhaust Header Manifold Tube Merge Collector 1.6"' 2.5"' Stainless | eBay
XMotorSports
XMotorSports and Cats were from JJC race and Rally. Silencer is exactly what it looks like a fire extingusher!

Coozer, lengths are within 3" of each other (couldn't get any nearer), mild steel (cost) and MIG'd at the mo, but might get someone to TIG it together.

ATB Dan.

Wow, good work.

I guess you've considered how you're going to have the bodywork so that you can get them on and off?
Also, is there plenty of room around the oil filter take-off?

Not trying to teach you how to suck eggs It's just that the exhaust packaging is probably the biggest PITA on mine, especially on the driver's side, and I ended taking them on and off again and again for various reasons, so make it as easy as you can!

Some thought has been given (but not that much I feel) the car will have removable Dax style side panels and only the upper aft section of the engine bay side panel will have a fully attached alloy panel. The Oil filter has a remove take off and remote mounted filter. There is about 3" clearance between it and the exhaust.

Gotta weld as much as possible in situ, them remove for fully welding.

ATB Dan.

Are you going to weld the 3 primaries into the collectors? I've been thinking about how to do my set up for the best, and can't decide if I should try to make the manifold a single piece or leave it separate and clamp it together. Clamping is much, much easier but leaves 3 potential places for leaks. Welding gives me a single easy to fit manifold each side, but it's much harder welding the inner edge of the final pipe to the collector.

Si, I was hoping to try and use a do-nut of exhaust sealer at the end of each primary to make a kind of formed seal and rely on springs and loops to keep the parts together.

My issue with clamps is that i have a 0.6mm discrepancy between the primaries and the collector and as you say welding is nearly impossible.

Regards Dan.

I cheated and used tubular headers off a 24v Alfa engine.

Well where's the fun in that!

Atb Dan.

[Edited on 20/2/15 by scutter]

I did get to make the other bits!
[IMG]http://i56.photobucket.com/albums/g185/moshty/LSRalfa/IMAG0308.jpg[/I MG]
[IMG]http://i56.photobucket.com/albums/g185/moshty/LSRalfa/IMAG0312.jpg[/I MG]

[Edited on 20/2/15 by owelly]

Mmmmm, is there a way of welding a 3-1 collector without making it look shite? I can think of a way of doing it with a few short sections, welding each one in turn until they're far enough apart to reach the middle, but I don't think it's very practical

I think I've just found out how to weld a collector without it being rubbish/impossible/leaking. But I think it only really works with formed collectors, rather than the tube ones.

If you get the primaries all lined up and fully welded, you can then weld a star plate into the gap between the pipe ends before adding the collector, thus sealing the centre of the pipes. It might need cleaning back a bit to get the collector in place, but that's no real bother. You then only need to weld round the outside of the collector, which is the bit you can reach.

Sounds simple, but I'm willing to bet it isn't!! I think I'll give this a go when I get to the point of welding my manifolds.

[Edited on 20/2/15 by DIY Si]

Just found this, not sure if it's any use:

http://honda-tech.com/welding-fabrication-53/merge-collector-fabrication-101-a-2787713/

To be honest, at £100 for a pair of merge collectors including postage, I'd by the ones that I used. I removed the outlet tube as it was to large and welded on a more suitable one.

ATB Dan.

If I didn't need to weld them up, I would do the same and just buy them. But I doubt I'll get all six sealed.