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#101 (permalink) | |
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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I previously had mine sandblasted, very efficient method!
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My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#102 (permalink) | |
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Code Goober
Join Date: Aug 2002
Location: Northern Virginia
Posts: 283
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Actually, he said:
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No, that's not a defect, that's a feature. |
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#103 (permalink) | |||
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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I have three manifolds I can test it with, stock 1.9l, 2.4l, and a cut down 3.0l.
I have these "Gorilla Mill" variable helix end mills I am looking forward to trying out.
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#106 (permalink) |
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Code Goober
Join Date: Aug 2002
Location: Northern Virginia
Posts: 283
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Very heavy = three interlocking pieces, each weighing ~100(ish?) pounds. That's just the buiness end though, stand and handle/monkeybar extra.
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No, that's not a defect, that's a feature. |
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#107 (permalink) |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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I don't know how they are shaped but sand blasting may be his best bet because any contours or odd angles are going to be a pain to do on a mill.
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#108 (permalink) | |
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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I have used custom header gaskets (1.9 and 2.2 type) on all performance applications. I used to have them made when I owned C & R. They have the divider between cyl #2 and #3. Not doing so skewed the ability to jet each cylinder correctly. Not sure it's much of an issue on a street engine, but for racing it's rather important. Plus not having the metal port 'surround' means I can port the gaskets (they were graphite with metal core) to match the head's port shape. Again, very critical for racing, as stock gaskets hang into the intake port tract! Bob
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My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#109 (permalink) |
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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I had it done professionally, cost me $2 per flange as I recall. Besides the ugly appearance of the mill scale, it makes proper TIG welding very difficult from contamination.
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My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#110 (permalink) | |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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Most so far seem to be for street vehicles so I am honestly not worried about the gaskets. If the few racers who said they wanted the flange and/or turbo header need a gasket made they can contact me. Otherwise I still plan to run with a regular gasket. I am considering running boost on the 2.4 I aquired… what kind of realistic gains from a stock engine would I see at 9 - 14lbs? If a 1.9L can hit 160ish with 8 - 9lbs of boost O_o I'm a bit worried that even during normal nonabusive driving I'd see reliability issues out of stock torque tube and rear end with a turbo or supercharged 2.4L.
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#111 (permalink) |
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Member 1000 Post Club
Join Date: Mar 2002
Location: Ft Smith, Arkansas
Posts: 1,481
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Once upon a time... OGTS was selling the Intake/Exhaust manifold gasket with a center divider in the #2/#3 hole. I believe they are in the process of having a new batch made...
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Paul |
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#113 (permalink) | |
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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HP depends on breathing, rpms, and turbo size. If you choose the same size turbo I did, expect about 15-20 more HP than me, but a heap load more torque at the same boost levels. At 150 hp with a turbo 2.4 I'd expect 200+ ft lbs of torque. More than enough to shred stock Opel parts! ![]() Bob
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My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#114 (permalink) |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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O-o Well it looks like I need to get searching on a solution for that problem!
The flange didn't arrive today so hopefully it will be here Monday.
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1972 Opel GT: 2.4, big brakes, efi - inprogress
Last edited by Gumby; 06-21-2008 at 03:14 AM. |
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#115 (permalink) |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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Update:
The flange didn't arrive yesterday. Maybe today! Rallybob - I measured the distance between the #2 and 3 cylinder exhaust ports on my 2.4L. It is a few 10ths over .2". Do you know how thick they made that on your design? I'm in the process of removing the manifolds from my 1.9 so we can get ready to do a mockup of the piping. I'll have the mild steel for the flanges this week so they could begin shipping as early as late next week. The turbo manifolds are still a ways off. I'm going to be gone three out of the 4 weekends in July for various military trainings so I am not sure how this will affect the timeline to completion yet.
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#116 (permalink) | |
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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So much for 'priority' mail! Thanks USPS....
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http://farm4.static.flickr.com/3077/...a21724e4_o.jpg This shows it pretty clearly!
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My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#117 (permalink) |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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That looks to be less than .1" - I'll wait to get your sample before I mess with the model in that area.
What are your recommendations on the tubes inner diameter at the individual exhaust ports and when they come together for the turbo?
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#118 (permalink) | |
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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On my wagon turbo header I used 'Schedule 10' fittings made from 304L stainless. Dimensions below.
__________________
My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#119 (permalink) | |
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Senior Contributor
Join Date: Oct 2002
Location: Kent Lakes, NY
Posts: 1,957
Real Name: Jeff
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Jeff '73 GT,5spd,Recaro,EDIS4 2.2 EFI by MegaSquirt, Ali Flywheel w/S10 Clutch, Electric Fan, Roller Rockers, Venolia Pistons, 6 Cyl Intake w/ Custom Injection, 15" Wheels,Lecarra,F&R Sway Bars,Custom Exhaust,1" Sport Spring,Koni Reds,Big Brakes,3 Core Ali Radiator,Hse of Colors Kandy Pagan Gold. 123 WHP @ 6800 RPM ![]() '64 VW Karmann Ghia '08 BMW M3 |
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#120 (permalink) | |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#121 (permalink) | |
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Senior Contributor
Join Date: Oct 2002
Location: Kent Lakes, NY
Posts: 1,957
Real Name: Jeff
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Jeff '73 GT,5spd,Recaro,EDIS4 2.2 EFI by MegaSquirt, Ali Flywheel w/S10 Clutch, Electric Fan, Roller Rockers, Venolia Pistons, 6 Cyl Intake w/ Custom Injection, 15" Wheels,Lecarra,F&R Sway Bars,Custom Exhaust,1" Sport Spring,Koni Reds,Big Brakes,3 Core Ali Radiator,Hse of Colors Kandy Pagan Gold. 123 WHP @ 6800 RPM ![]() '64 VW Karmann Ghia '08 BMW M3 |
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#122 (permalink) |
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Member 1000 Post Club
Join Date: Mar 2002
Location: Ft Smith, Arkansas
Posts: 1,481
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The problem I found was interference with the thermostat housing. The other tweaks were very small adjustments with the bolt clearance holes to improve the ability to get all the manifolds bolts in easily. We're talking .020 to .030 nothing major.
I cut mine on the water jet at work. First, I cut it on 18 ga sheet metal and kept making very small adjustments, checking against the 3 heads I have.... and then cut one out of 3/8 hot rolled plate. I made mine so it would fit a head modified to Bob's street porting article, which should still work okay with the stock head.
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Paul |
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#123 (permalink) |
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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I received Rallybob's version of the flange today. The divider between the two cylinders is about .1" and I also noticed that the thickness of the flange is actually less than 3/8"... The sand blasting removed about .004" from each side.
A few other things I noticed. This flange has a 1.22" width for each exhaust port but the 2.4" manifold I have various from 1.38 - 1.42". So it is a bit larger. Is there merit to using one size over the other? In either case the width is larger than the exhaust ports. I can faithfully copy Bob's design or just as easily make any improvements. Is there any census as to which way to go?
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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#124 (permalink) | |||
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Project 1450 supporter...
Join Date: Mar 2002
Location: Pleasant Valley, CT
Posts: 7,436
Real Name: Bob Legere
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Bob
__________________
My Flickr photos. Jan. 3, 1984 - Jan. 3, 2009, that's 25 years of this damn Opelitis! C.R.L. 9/22/69 - 12/8/99, J.M.L. 3/3/43 - 6/15/04 |
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#125 (permalink) | ||
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Supercharged 2.4
Join Date: Mar 2006
Location: Oregon
Posts: 619
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I'll get cracking on the updated model this week.
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1972 Opel GT: 2.4, big brakes, efi - inprogress
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