For flow restrictions I'm not concerned I'm running 1.75" primaries because it's what was on the scrap headers I had. So bumps and irregularities may create a bit of turbulence, but with the primaries being so large I have plenty of give/take for a large boundary layer.
I don't disagree with Prine on much of anything, he just functions on a different budget than I do.
I've read through mad darts build and he has very impressive welding/fab skills. And I'm sure he has been doing this a lot longer than I have which is why I ask what he isn't sure about. Saying you're not sure, but then providing now explanation won't help me learn.
I'm not new to turbos or anything of the nature. I'm a senior mechanical engineering student and just finished up fluids 2. If I have to i can tell you just how inefficient my headers will be. How ever through studies I've read the differences between mandrel tuned headers and a log manifold are negligible at the power levels I'm playing at.
We'll to be honest, what you see me building is my very
first Turbo Build. I knew nothing about them 6 months ago. Yes I have been around cars since I was a kid. My Triangulated 4 Link & Minitub is the
first that I have ever done. All the fab stuff you have seen me do is my very
first attempt at doing it. I have rebuilt engines and can fix just about anything if given enough time. Electrical or whatever.
I however previously 15 years ago worked as a metal stud framer/fabricator/welder for 14 Years building some of the craziest things you would ever see when walking up to or into a building. Dome ceilings, Serpentine soffits "details in ceilings" , barrel ceilings........and those crazy walls, ceilings and floors you see at places like disneyland etc, "I worked at Disneyland building there crazy stuff for quite a few years" where nothing is ordinary.
I understand you are on a budget but I believe you could take a little more time with your fabricating/welding. It doesn't take much more to try and do a better job is what I am trying to say. You could get header flanges for about $35.00 and use steel plumbing pipe elbows & straight pieces for probably $20.00 per side. Run those right into a home made turbo flange and then bolt on your turbo's. It also looks like you may be using the wrong wire, speed settings and Heat settings when welding. The most common size wire is 030. I use 030 flux core for outside welding jobs where there is wind I use standard 030 wire and a 75/25 mix when using gas. I do not own a TIG welder so I take that stuff in after I tack the parts in place. " Probably going to buy one this year " I know I could pick right up on using a TIG. I use to OXY/Acettaline weld a whole bunch when I was a kid. The concept is the same accept TIG looks a whole bunch EASIER to me. Guys make a big deal about it but I know it can't be that hard to do.
The internal wiring of your machine will need to be reversed if you are switching form Flux Core wire to solid wire and a gas bottle also.... Check your settings they could be wrong. It also looks like you may be using Solid core wire that requires the use of gas, something else to check.
Some tips.
1) Clean your parts to be welded before welding
2) Clean your welding tip
3) Clean your welding hood, actually take it apart and windex the lenses etc.
4) Use protective gear so you don't get burned and jump OFF TRACK when welding.
5) Practice on scrap metal to hone your welding skills before welding the real parts.
6) Go to youtube.com and watch some welding video's. This will give you an idea of how to set your speed and what kind of sound a good penetrating weld makes and what they should look like.
I don't believe your headers now will last very long and like Prine was saying could Ruin your turbo's and your engine before you even get a chance to drive the car.
Also a 15k paint job will not hide bad body work. It will bring it out more and you will see everywhere that it was done shabby. Same with Ceramic Coating. If the part does not look that good before coating. It will look even worse after.
I hope that helps.
