O2 Housing Project

[blageo23]

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.

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


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


(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)


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.

[User Name]

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

[turbotalon1g]

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

[carltalon]

You could get a farward facing oil filter housing.

[sleepydsm]

Originally Posted by carltalon

You could get a farward facing oil filter housing.

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

[Shane@DBPerformance]

Does the alternator fit?

[GsXtUrBo98]

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

[blageo23]

Originally Posted by ecoli

Does the alternator fit?

it does. By like 1-1.5"

[95talonracer]

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?

[sleepydsm]

Originally Posted by 95talonracer

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?

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

[Kevin 1G Drummer]

Originally Posted by blageo23

it does. By like 1-1.5"

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

[blageo23]

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.

[FattyBoomBatty]

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

[Archertsi]

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.

[blageo23]

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!

[Pushit2.0]

Originally Posted by Archertsi

...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.

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

[Archertsi]

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.

[Archertsi]

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.

[sleepydsm]

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

[Goat Blower]

Originally Posted by Archertsi

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.

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.