O2 Housing Project
 

I didnt want to spend $300 on an o2 housing so Im going to make my own.
Its going to be an O2/downpipe all in one.
http://i259.photobucket.com/albums/h...e/CIMG1943.jpg
2.5"vband clamp
3" U bend Pipe

This is what I needed a spare engine for and headbolts. Even tho I never got headbolts I zip tied the head to the block :)
http://i259.photobucket.com/albums/h...e/CIMG1940.jpg

First thing I did was chop up the Ubend. Then I tacked the cut piece to the Vband flange

http://i259.photobucket.com/albums/h...e/CIMG1944.jpg
(dont worry about that pipe where the wastegate goes. It came with the turbo and will not be going on my car. It was used for moch up and thats it)
http://i259.photobucket.com/albums/h...e/CIMG1945.jpg

And after all of that the Idea will not work. I forgot about the oil filter. I had no Idea that it stuck out as far as it does.
Next step is to order a different pipe that has a smaller radius(looks like it will work alot better).

Kind of a worthless thread as it didnt work but I will add more as I continue to make it.

Re: O2 Housing Project
 

Honestly, that's a hell of an idea, and it does look fun! Keep us updated with pics/info for sure!

Re: O2 Housing Project
 

Nice, hopefully it turns out as good as you want it.

Re: O2 Housing Project
 

You could get a farward facing oil filter housing.

Re: O2 Housing Project
 

Yeah, Blageo told me about that last night, a Buschur part from their RWD stuff.

Re: O2 Housing Project
 

Does the alternator fit?

Re: O2 Housing Project
 

Lookin good i'll have to stop over to see the progress...

Re: O2 Housing Project
 

it does. By like 1-1.5"

Re: O2 Housing Project
 

Hey I told you to come and get the bolts you need foo! I have a bunch of them. Are you routing the wastegate back into the exhaust and no external dump?

Re: O2 Housing Project
 

Mike- Zip ties worked fine, he doesnt know yet about dumping or not.

Re: O2 Housing Project
 

Better put some header wrap on it, otherwise you'll be cooking an alternator every couple months.

Re: O2 Housing Project
 

Im going to make a heatshield for the alternator and it will not be that close once I get the new pipe and make it better.

Re: O2 Housing Project
 

Instead of buying an expensive buscher oil filter housing, couldn't you just go get one off a mighty max in a junkyard?

Re: O2 Housing Project
 

Looks good so far, too bad you couldnt have gotten a tighter u-bend. Here is a couple pics of mine that I built. 3 inch all the way. I have a few tips listed below.


You dont need much room to clear the oil filter. One thing that I did was belt sand the side of the v-band flange that goes to the down pipe. I sanded it at a slight angle, then sanded the end of the pipe that met it at the same angle so they were slightley oval, this gave it more angle for a sharper bend immediatley off the turbo. But you do not want to "pie cut" the pipe to make sharper bends. This creates "steps" on the inside of the bend. When the exhaust goes over these "steps", it start to tumble or "roll" back over itself. This inturn creates turbulance and slows exhaust flow.

Re: O2 Housing Project
 

Looks good! Thanks for the tips!
I ordered a new Piece that is 120 degrees and looks to have a better radius. That should be here on thursday!

Re: O2 Housing Project
 

But sanding the flange and pipe makes it a pie cut. That is a little to much thought and insight for the average DSMer who just says "get'er done", as cheap and easy as possible of course. I would guess the slip connection makes a few people ask, will that leak?

~Jon

Re: O2 Housing Project
 

It shouldnt leak, its been done coutless times, the exhaust is flowing the other direction. Even if there is a small leak, I dont care, most people dump them to the ground and that is way louder. I'll never hear a small leak.

Yes I guess I would consider it a slight pie cut, but it's immediate. You hafto sacrafice somewhere. Look at an fp o2 housing, they pie cut it like crazy! And they dont even purge weld it. Also the v band flange that I used was from fp, it flares from 2.5 inch to 3 inch, so the angle that it made matches the angle of the curved pipe on the inside of the radius so there is no step. Ill try to snap a pic of that today so you can see what I mean, it's what really helped me make the difference between clearing and not clearing.

I did nothing in my build with a "git er done" thought of mind, that's what makes dsmers look bad in the import crowd.

Re: O2 Housing Project
 

Actually you can kinda see it here. Look at my first weld to the v-band flange.




Click on this pic and then click on the full size image, you can really see the inside of the bend.

Here is my first sad attempt at an 02 housing. I pie cut it, because I didnt know what I was doing. Tried to copy fp's 02 housing. There is one thing you could try that I did do with this. I angled it forward first, then turned it down. This gets it away from the alternator and oil filter.

Re: O2 Housing Project
 

Is the purpose of the slip fit for the dump tube to aid in removal of the wastegate?

Re: O2 Housing Project
 

Amen. I look at some of the stuff out there and just shake my head. I suppose that's what happens when you can buy a DSM for $1500 these days.

BTW, I absolutely love your downpipe. It's almost exactly what I ended up with when I had 3" Hahn Racecraft dowpipe/02 housing and routed the external into the pipe, but yours is nicer. That Hahn was a nice piece, just needed something a little bigger. :spin:

Re: O2 Housing Project
 

Yes this helps line everything up for the wastegate when installing it or removing it.

Thanks Steve, next time your in town you should come check it out.

Having access to my work helps allot. I only posted this so I could give some tips with my experience in this area. I actually was given some pointers from a guy named Dave Piekarski, he owns DPengineering and has allot to do with the cup car racing. He has a shop in Charolette NC for that, but is origionally from Fergus Falls MN, and he invented the square tube header. We needed a custom set of headers built at my work and he was hired for the build. Dave was the one who taught me how to tig weld and also gave me these pointers. He was very interested in what I was building and over looked my work while I built this new downpipe. Dave assures me I should see a better spool up time vs using a pie cut piece.

He claims it would be even better if the pipe were square, lol.

Re: O2 Housing Project
 

Square? I've never heard of that. I would think the air would travel more slowly in the four corners, but what do I know, I'm no fluid dynamics expert.

I'll drop by there sometime when I deliver a car or something. Other than that, I'm only up on weekends, like Grandma's next Saturday.

Re: O2 Housing Project
 

Sadly I will be in Canada for a race Saturday. Talk to Brian next time you come up, I would be interested to talk to you about some of the things we have been disscussing that's 2.4 related.

Dave figured out that with a square tube primary, you have more surface area than with a round priamary. Kinda like a kicker square solo baric sub woofer vs a round one. Using a square tube you can use a smaller primary for the those tighter areas and still have the same volume that a larger round pipe would use. He also figured out that with a tight bend in a round pipe the exhaust starts to "roll" over itself and begins to spiral, slowing the exhaust speed. With a square tube, it doesnt spiral and actually the tighter the bend the better. On the inside of the bend exhaust speeds will actually increase and draw the exhaust out.

He has huge patents on anything automotive related that uses a square tube for exhaust, etc. Currentley he works with chevrolet and ford using this technology and you will also see his square tube headers allot in dirt track racing. Look at a new corvette, cast square tube exhaust manifolds.

Any way, sorry to wander off the subject

Re: O2 Housing Project
 

Back on subject...
I got the new pipe yesterday and I spent the day getting it cut up and tacked together. Turned out pretty good for not having good tools!
The old(right) and the new(left)
http://i259.photobucket.com/albums/h...e/CIMG1946.jpg

http://i259.photobucket.com/albums/h...e/CIMG1947.jpg

Plenty of room for the oil filter now. that is about 1"+ out from where it would sit normally, and about .5" higher.
http://i259.photobucket.com/albums/h...e/CIMG1948.jpg

Cut up the old pipe and made it connect to the bottom going back.
http://i259.photobucket.com/albums/h...e/CIMG1949.jpg

http://i259.photobucket.com/albums/h...e/CIMG1951.jpg

http://i259.photobucket.com/albums/h...e/CIMG1952.jpg

From the back
http://i259.photobucket.com/albums/h...e/CIMG1953.jpg

All in all it turned out pretty good. I still have to make the joint inbetween the 2 pipes fit better but I wanted to make sure I had the angles right.

Re: O2 Housing Project
 

Hey you are going to put in a flex section right? Also have you decided if you are going to route the WG into the DP?

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Flex section, yes. And I think Im going to route the WG back into the downpipe.

Re: O2 Housing Project
 

Looks pretty clean and I bet it would flow real good.

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I like it alot!!

Re: O2 Housing Project
 

Looks clean, nice job sofar.