Shaping a Turbo Exhaust Manifold Part 1
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- Опубліковано 16 вер 2024
- This two part video will show how I machine the flange face on a stainless turbo exhaust manifold using my G&E shaper. First video will show how I set it up in the shaper and get it indicated level and true.
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Watching him helps me reassure myself that I am not a half bad machinist. He is pro level.
He does almost everything in the same fashion as I would.
We are using the big belt sander to fix those flanges. Very common not only with Coyote manifolds.
The problem is with a design of a flange. First of all make them from mild steel - keep the tubing stainless but go mild for flange. Stainless warps like crazy even with proper tooling. We design our own turbo manifolds so we know the pain.
Next, you can design the flange in a way it will not warp that much - cut some holes are make them almost like 4 separate flanges it will help a lot.
Greetings from Poland Adam!
I'm always amazed about the thought you put in your setup I learned so much
These new fangled shaper things are going to replace cnc mills one day.
Haha I was just about to comment something along those lines
That dial! I can read it from space! This is the greatest thing I've seen in a shop🤣❤
Adam, when you showed your grill & remote temperature indicator, it reminded me that you were on a diet that you used to report on. Are you now at the weight that you wanted?
This video about the set-up is interesting because we get to see the details of what you _have_ to do to hold a warped, irregular part like this. Thanks for posting this!
It’s so cool to watch someone expertly using complex tools that I’d never even heard of - it’s inspiring Adam! Thanks for sharing these with us!
I just watched a 30min video about putting a piece of metal into a vise...
If Adam made a video about paint drying, I'd watch at 0.5x speed so I don't miss anything.
Literally everything he does and comments on becomes interesting.
I'd watch him count all the sand grains on a beach and then ask for part 2.
I enjoy his videos but i watch all of them at 1.5x or even 1.75x . he's a slow talker so at faster speeds he's still understandable and it lets me watch more of his videos in a shorter time
I've been a hobbiest "machinist" for a while and your thought process teaches me literally tons of things to make it easier. You've played the game a while and know the order of operations in your head
Nice set up, I like how you utilized the coupling nut 😊. The challenge of work holding is 3/4 the battle sometimes lol. Can't wait for part 2! Cheers 👍😁👍
I really enjoy the setup portions of the videos. It is interesting to see how you dial in each job before cutting.
Fact, welded assemblies distort. Many fail to realize this. You are correct in that the order of operations to make good parts matters. Funny a couple of years ago you would not have wanted to do this job because of how long it would take. Now with this your job you can dedicated the time and not have to worry about it eating all of yours. 😎
Your finesse to tackle an Abom size job is a pleasure to watch, making it a blessing to learn from you. Just great.
I always like doing those tougher setups. That's a large part of the enjoyment for me anyway. Done a few manifolds on the shaper myself 👍. Thanks for sharing Adam.
It would be very interesting if you, Brian and Adam each did a similar project to this so you could compare your individual approaches to the job. Just a thought
Best way to show gaps when holding a straight edge up to something on camera is to shine a little light behind it. Viewers can see the gap changing by the light shining through changing in intensity.
I think I saw Tom at Oxtools do it :)
That universal table is brilliant, even you Adam would struggle to set that parallel without it, brilliant job.
Love that big Starrett guage! Must've cost a pretty penny.
I often wonder why you tend to favour the shaper in situations where you might expect the work to be done on the mill, but actually seeing that universal table in action, it makes perfect sense now, that table is amazing
He just does. He's made that way.
Thats an awesome machine...For something so big the fine adjustments you can make is incredable...Onto part 2
you should make a cologne that's a mix between cutting oil smoke and barbecue smoke.. the manliest of all colognes.. lol. love your videos, you truly have a master's touch when dialing in your work.
Throw in a whiff of gunpowder and I think you have a winner!
A touch of Hoppe's #9 too please.
I want the part2 right now.
I absolutely love the shaper! It is by far my favorite machine that you have! not to mention it's very satisfying when you use it- keep up the good work!
Shaping heads, manifolds, decking parts - making anything 1000% square dead nuts, my favorite episodes ;) Keep up the great work Adam, been with ya since the beginning.
Man, that shaper is one heck of a machine. Looking forward to the cut. Thanks, Adam.
In my day we ran a bead of weld around the ports on the flange. Then partially machined it off and rewelded any low spots and remachined until we had a projection around the ports standing proud of the flange. This crimped the gasket for a wonderful seal.
Love the old blind guy indicator.
Love the way you show how to good these irregular shaped items and everything you do to ensure they are held tight and don't slip.
Great video as usual, but copper RTV instead of gaskets would seal that up in a heartbeat. I've been using copper RTV instead of gaskets on headers for a decade now and I've never had a failure. You'd be amazed how far off most headers are. And after some use, they warp more. I usually hit them with a belt sander just to flatten them out, but the RTV trick works wonders. I have had a ton of gaskets blow out back when I used to use them.
Hello Adam. I'd like to say that I sure enjoy your videos and that I hope there's a young person in your life that you're passing your knowledge on to. I had the good fortune to know someone in an automotive machine shop that passed a lot of his knowledge to me. I will always be thankful for it. Thanks again for sharing.
That indicator is fantastic!
yea I want one too
I love that huge Starrett dial!
These set ups are fascinating.
I am luvin' the Starrette indicator, now us old foggy machinists can read the dern thing.
Awesome use of those parallels. Love seeing new tips and tricks like that.
When you’re not using that indicator, you should put it on a big gold chain and wear around your neck.
LOL Love this idea! "Abom Flav" 🤣
Love the new intro music!
When that indicator came on screen I thought it was a wall clock.
That universal table sure is useful. I imagine setting this up on a mill would have been a real challenge.
I have a new appreciation for old machinery, really likin' the shaper!
Hey you weren't kidding when you said you'd break out the BIG indicator 🤣
hehe so now Gentle Giant is making metalworking and cooking together! hmmm i like it!
That flange is a bit thin and probably wasn't stress relieved. It will warp when heated up. Even after you flattened it, he may still have troubles. The metallurgy on cheaper parts is horrid.
I'm like a kid in a candy store when you put a video out. Thanks bro 👊
Was looking for part 2. Seen you didn't make it yet and was like damn 😅
That table is so cool.
Haha haven’t seen that huge Starrett indicator before, that thing is awesome!!
I love how much you put into the setup alone . Awesome video keep it up
Looks like whoever welded that steel weren't watching the tamp and just went to town. Twisted that metal like a toy!
Awesome work, Abom!
1:31 - Hell yeah! It's so cool (for me) to see you using that straight edge I ground.
I would also think it's cool. Pride in what you do is priceless!
That straight edges is great Pete! Thanks again!
I feel like everything that you buy how you have to work on or fix it immediately I see why you like your old machines!!
Great video as usual thank man
Darn, I was waiting for some pulled pork shots at the end of the video. LOL!
Just like painting and other jobs; It's all in the preparation.
With long tube headers we always cut the flange between each exhaust port to let them move to make up for any differences
I love those shaper videos. Wish I had one of my own, there was only one thing wrong with that video. Don't show more foodstuffs, I was drooling for like an hour after that 😂😂
Adam, just love your channel, has taught me loads about machining , cheers pal
I love how some tell he is doing it wrong, Do it this way, should have done this or that. I know, you do it and show all how it should be done.
Cut between the ports, I had this problem years ago
You can straight edge 100 exhaust manifolds and I assure you 100 exhaust manifolds are going to measure warped. The stresses on that from the welds and the way the tubes pull on the part and then the heating and cooling cycle will keep them nice and warped.
I reckon Phil should just send you this shite *before* he fits it. That way at least you'd keep your hands clean! Heh! He could pay a retainer, you be be like some sort of manifold lawyer :-)
I *love* shaper work.
Awesome job Adam. I love to watch this kind of thing.
I love your content so much man.... every video just seems to get better and better.... really seems like your finding a very unique style with it
Way to build suspense! Checkmate, Hitchcock! Seriously though, thanks for taking the time to share your experience. We all need more teachers
I Enjoy the G&E shaper projects Best one yet Thx You Sir.
The stainless manifolds I have welded where all welded on a 40mm thick piece of steel with as much clamps as possible.
Didnt need any machining on those.
Adam! GREAT you changed the music for your videos. It is so much better now
Wonderful machine, looking forward to seeing part 2
I really love your videos. It's time to retire from racing so I'm going to sell my cars and get a mini lathe and start learning.
Good morning Adam the amount of steps and care that goes in to the set up is amazing . One of the machine shops that did V. W. Heads For us would bolt the head to a thick steel plate, put it in the oven , over night than finish the surface the next day , there thought was to straighten the head then make it flat ..
Gday Adam. The universal table really shines here with jobs and setups like this, it would be a lot more involved in setups without it, I’m looking forward to part 2, thank you sharing, take care Matty
Great video Adam the weight loss looks great you look like a new man mate enjoyed the video as usual great content stay safe all the best mate god bless
Love the channel, I'v learnt so much and understand setup better than ever before. Thank you Abom79 !!
me too!
Dammit. Have to wait for part 2!
Someone's poor workmanship is another job for Adam. And some entertainment for us.
What time's dinner? As a kid in the 60's, the Navy guys use to come back from Japan with the clay Kamado's. I think they were $9 back then (340yen to the dollar back then.) I have a newer one like your's but also a couple of vintage one's, one of those I cook on, probably 250 nights a year. It's a great tool.
That's a challenging work holding sitiation. On the flange bolts turn round rod/ projection that comes up shy of the gasket surface on one side and the table on the other. so they almost pound in the bolt holes love your toe clamp set up your taking light cuts. the round rod will help maintain flatness under the cut pressure. man pulled pork for dinner thats just a dream here love it adam thanks
Great video! If that is for a turbo kit, it's a single turbo kit, that's the crossover side as it doesn't have a flange to bolt a turbo to. The flange on the end is for v-band.
So, in other words, they should pull the other manifold for machining as well, as it's probably a ticking time bomb...
My guess is that the problem is gonna return due to the aspect ratio of the flange .. it might make sense to break the flange in the middle so that the expansion is taken up by the SS pipes
It's stainless, you can count on it to warp no matter how you weld it. Machine it after is the only way. Bolting it is just delaying it warping until you remove the bolts!
david n Hi David. Noobie question here. Are there grades of steel that are particularly resistant to warping? Thanx
The big gauge is great for the camera!
Great job. Lot's of work planning and getting ready to start job.
Lol! "Unflat" love it agreat description.
Great video. Nice options on setup on shaper. Thank you for sharing.
I can’t see how someone could make a manifold and not machine/flatten the flange. They will always warp when welded. Nice fix Adam👍
You are a master my man.... truly awesome instructional video!
Wow ! I can read that Starrett dial without my glasses !
I'll have to wait for part 2, but I find it hard to believe that that vice can provide enough clamping force without bending those tubes to secure the part for this type of "broaching" operation.
Broaching? Why did you say broaching, and why did you put it in quotes?
@@xenonram I put in quotes because I was not certain it was the right term for that machine tool operation. In high volume production, cylinder heads and closed deck engine blocks a "broached" in 1 pass.
It's on the engine builder to make sure the deck of the block, the heads, intake, and exhaust are flat and don't leak. Don't even think about building an engine without a trip to the machine shop.
Yes there is a welding fixture, we never machined them, but you have to know how to work your heat. I would bet thats a Chinese manifold.
I needed this exact job done SO BADLY a few weeks ago. My machinest did an AWEFUL job!!! 😭😭😭😭
Could almost taste that pork roast over here in the UK :-)
Such a cool video. Looking forward to part 2.
I wanna come eat at the Abom79 house! Everything you make looks Sooo good!
Very cool vid abom love the content. I have actually recently made a few axhaust manifolds myself and yes typically we do clamp them down to weld but even after they still seem to wonna spring out. Normally shops do use a belt sander your right but im thinking of taking it to work and sticking it on the bridgeport. Perks of being a apprentice machinist i guess lol
"Abom-size" indicator dial....
Great video Adam. So clearly explained. And so masterfully set up. Can't wait to see the finished aŕticke. Remind me again what the minimum step over is on that shaper . Please.
Man, that dIal indicator is Da Bomb, Abom.
I think a big part of the problem was the lousy gaskets used. Looked like el-cheapo Fel-Pro/McCord type gaskets, which most likely caused a lot of the warping. Multi-Layer Stainless gaskets would have been a better choice.
Agreed, that and possibly poor torque sequence.
FWIW: when i was younger we worked on alot of GMC motorhomes, they used cast iron manifolds. the best trick to fix the exhaust was to put brand new "green" cast iron manifolds on, send it out and drive it hard up long hills. they would always come back w/exhaust leaks, then you'd pull the manifolds again and send them out and have them machined flat perfect. they'd usually never have another manifold problem again. i wonder if the same thing happens to steel headers like the one Abom did such a nice job on.
Badass as always! Shapers are awesome. Big industrial monster but just cat like. Love all the videos. Gives a home machinist like me something to shoot for!
Wow. Even your dial indicators are abom-sized.
Laser cut out of flat material, not heat treated will always warp when welded especially stainless. Also probably cooled after removed from the jig, if they even had one making it.