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Performing a MIRACLE on a 3600HP Diesel Engine (Turbo Manifold Build)
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- čas přidán 23. 05. 2024
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Glease Manufacturing is a Canadian Job Shop serving Southern Ontario. Our CZcams channel uploads new videos every other Friday at 3:30PM ET.
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Production by: @LVMDigitalProductions
Thanks for watching!
#Diesel #pullingtractor #duramax #fabrication #machining #custom #metalwork #headers #tigwelding
Your weekly reminder to get the coolant sorted on the lathe :)
Can't say enough how much I appreciate it! A few more weeks of nagging is all I'm gonna need.
Incase anyone was wondering what the engine is it’s a Wagler DX460 with an inline mechanical P8700 injection pump. Other duramax engines for common rail injection systems (all injectors on each bank feed from one common rail). The P8700 series of injection pumps are 8 cylinder big brother of the P7600 version found on 1994-1998 Cummins 12V engines.
Is that like a Diesel version of a Wankel?😅 (the names we get sometimes)
Wild to see 1-5/8" headers making 450hp per runner to begin with! I'm sure it's going to like the upgrade :)
Fantastic video and huge props for documenting it along the way, really dig it and looking forward to more
Hey thanks so much you guys, I can't say enough how fond I am of your work! Yeah I was definitely surprised to see the power it was making on what we initially built.
That's probably one of the best video about building this sort of things I ever watched. I'm a Tig welder myself and it's so enjoyable to watch, I'm waiting for next video now 😎👨🏭
Wow thanks so much!
I have fabricated headers for myself out of mild steel. It was a learning experience and the next set will be stainless. Excellent work!
Nice! Best of luck 🤙
Working with stainless and managing the heat is a complete PIA… hats off
"Struggle until its done" is how we all do it lol!
I love it.
I’ve built a few stainless two stroke pipes.
I hard a tough time turning the flanges and purging… at first.
Awesome, I was actually thinking of building a set of headers for my 7.3 idi since no one makes them anymore. I’ve done full exhaust systems on several cars and trucks just by buying several different J, 180, 90 etc bends but have yet to dive into making headers. I weld for my day job so I’m not worried about it too much just knowing there is a ton of work involved I gotta get myself motivated. I found building the exhaust systems was both enjoyable and satisfying when I was done and really liked being able to get them to look and fit exactly how I wanted.
Your last 2 manifold building videos have been very insightful and have picked up some helpful stuff from you. Very much appreciated!
That's music to my ears, so glad to hear it!
Glease Man this video is a serious flex. Awesome work. You should be very proud of yourself.
You can use silicon bronze brazing rod, no purging and it comes out beautiful and it's strong as hell
Heard the Lord Mention in the end of the video, Appriciete the message, the Fab skills and putting some more pieces together. I could do this kinda work and engine building!!
Mr Gleaseman, I am a Canadian worked in the field for over 40 years and would like to give some of my ideas if you're interested.
You're doing a great job, I enjoy watching your show. 🤜
Please do!!
12:12 if I hadn't already subscribed during the last edit gag, I'd've done it here because that was hilarious
So cool to see these projects being made in kingsville, much love from MC3 Manufacturing!!
Thanks, I appreciate the love!
That is some pretty wild accessibility on that toilet
Love the copper faced hammer, this guy has talent and a craftsman!
Very nicely done indeed!!!
It was the toilet part that made me subscribe, LOL... actually seeing you chamfer that tiny area with the dremel makes me think that's the kinda guy who can't keep from detailing anything he touches... I was wondering if argon back gassing was done during final welding...
AMAZING end product!
Great work 👍🏾
Thanks!
Awesome work dude love learning with every vid 😎😎
I am also Canadian and weld stainless steel exhaust stuff! Cheers!
Right on! Cheers!
Subscribed!
Crazy good final product!
And that motor is on an other level..!
Top notch work there!
Thank you!
Awesome video!. I always love watching manifold builds…. Those outtakes at the end have me in tears!. There’s nothing worse than looking back at footage, realising your head is covering the shot! Hahaha I look forward to the next video.
Haha thanks so much man
Those headers were warm alright 😮
Your work is simply next level in everyway possible, even your video making skills are incredible. gem of a channel and fellow Canadian
Wow, thank you! I gotta give all video credit to Leandra who's films and edits it all!
She is pretty great
Thank you for the opportunity to learn homies!
I thought you were going to use a tubular dolly and shape the collector to match your tubes better.
Love those billet collectors.
Imagine welding everything up, and then 3d scanning the tubes where they collect. Then using that scan to cnc a custom billet collector. 😂
Just saying 🇦🇺🤜🏼🤛🏼😎☮️🍀😂
Lol. Had a giggle there, when you mentioned that you were not welding without gloves, but that you were tacking. You would've gotten a thousand comments on that. But it reminded me of the stupid things I did when I was younger (late teens or early twenties) From the way I drove my car to yes welding things. I welded pig pen divider for our farm, all day long in just shorts and a hand held welding face shield. Should I put a 😂 or 😠? Now in my fifties, thank God I still have a nice skin (sort of). The things people did and could do back then without being harassed. Just started watching your video's. 👍👍
I can relate far too much your story 🤣🤣
Thanks for the follow!
what a good channel!
You might think it's okay to tack without gloves. So did I. Developed two consecutive stage 2 skin cancers after some time.
Long sleeve shirts and gloves all the time ever since. Even if it's just some cheap thin gloves for just tacking and then heavier gloves for full welds. It's definitely worth to spend that few seconds putting them on compared to the dreaded visits to doctor every 6 months to find out whether or not it came back or not.
Looks great, thanks for the video 👍
Thanks, appreciate it!
Another fantastic video really enjoying the fantastic work and skills
Thanks a lot!
Nope ! I checked I am subscribed. Dont need no reminder lol 😁 Don’t forget about the lathe coolant! Smooth move lapping the header flanges. Be Safe!
Haha, thanks a lot!
Question, The second pulling truck ( when the engine blew), did he have to get a new pair of underwear? Your attention to detail on the header build is top level, bolt spacing and tube orientation.👍👍 I will probably never build a set of headers but will definitely use some of your tips on other projects. Be Safe!
I too was pushing out content when I watched your video. I just finished my first set of headers on my e30 twin turbo v8 conversion and only just made it through wanting to only kill 3 people.
A lot of swearing and recutting and tacking in not very favourable positions. Using magnets as extra hands only to sack the lot of them after the job was done. Many prays to the lord Jesus through this part of the build. You can literally say that these headers actually brought me closer to god ,after repenting for the swearing and thought of murder. 😂
Thank you for re traumatising me with this video of the extra steps of using stainless next time.
Seriously brother love your work just found you on the tube and you now have a new subscriber.
God bless. I’m off for some more panadol for the headache I feel coming back on.
😂😂😂😂
Hey I’ve been thinking about making custom headers and manifolds for a while now. I have the skill I just don’t know how to find the clientele. If you could share what you did when you were first starting out to get your name out there and bring in clients that would be awesome!
I appreciate the question, and I'm going to answer that in detail in a video coming up soon!
You need some ice engine works header molding blocks
Any idea on EMAP pressure? I’m running V bands at over 200psi exhaust back pressure with absolutely no issue in a customers diesel (when VNT angle is shallow) have also seen V bands go 300-400psi in other applications. Pretty wild to see one snap a clamp, especially running a pressed collector which would balloon well before I’d ever expect a V band to fail,
Manifolds look killer man! Nice work!
Considering how much these guys are dumping money on those engines would 3d printed inconel runners be an option? Gls fab also sells 2"x3" and 2,5"x4" billet merges with machined flanges on them. Also elmer racing does as well but don't know how easy they are to get on that side of the bond.
You make a good video and header. The one time I tried to weld aluminum, it went from cold to total meltdown in nothing flat, who knows with steel. Any good pointers or suggestions? Thanks Ron
i just watched a guy build a manifold.
Yes!
Out of curiosity, when building headers from scratch is it easier to tack it up physically in the car? Or do you ever take a good look at stuff they can’t run into, build your jig based on the stock header and then double check that your new design fits before welding it. I’m just imagining the process of tacking up in vehicles with tight engine bays and that seems almost impossible! Love the content though!
Awesome 👍
Wow I didn't know stainless could take so much abuse and not crack. I thought the old ones might be inconel after seeing that pull.
321ss is badass!
Back purging root pass total sense. But in a different video you did (forgot to ask then) you back purged during fill pass. Could you explain why you did that? Im trying to learn, no criticism intended . Thanks and great job!
Great question! It's a bit wasteful but I just like how clean it makes the insides look. Not necessary though.
I clicked the like button for the toilet scene lol.
Who makes that little deburring tool you use? Would be nice and handy to have something small like that!
Hah, thanks a lot man really appreciate it.
It's one of these, watch eBay for em:
www.gessweincanada.com/product-p/850-7230m.htm
What’s the purpose of the back purging?
I use welded nuts instead of bungholes on my projects, but one issue i've found is the nut tends to wander off center over the hole leading to the bung damaging its threads against the hole side. do you dremel out the rear of the bung to avoid this?
So do the rules for sled pulls require the turbo system to remain within the bodywork? I feel like you could optimize the headers more if you could go through the hood a bit.
Possibly, but the truck is 4hrs away from me so I was only working in that space I knew I had
I would love to get the stl for those modular 3D printed bends!
Here ya go! www.thingiverse.com/thing:2305656/comments
@@gleaseman thank you! Love your content. Keep it up
your videos are very good!
I have a question, I saw that the flange you used on the cylinder head is very thick. For Otto engines (gasoline), what would be the minimum thickness of the flange? Thanks.
Thanks! I wouldn't go less than 3/8" because you lose some when you sand the bottom flat. Usually 1/2" plenty overkill for most applications.
@@gleaseman thankyou ;)
Hey, so I'm on the young side of adulthood and was wondering does making header's (welds) have to be pretty? Or could you do let say an "Okay-ish" job could you grind out the imperfections. I'm only asking since I have no real welding experience. Also I do really like watching you do this stuff makes me envious in good way, almost like admiration to how skilled you'd have to be. Sorry for the long comment, but I do really wanna know. (Also it's my first comment on your channel ever so sorry again for it being so long)
5" stainless steel shaft. $$$$$
Why stainless steel because of the heat cycles it has in built redundancy, it just keeps getting more and more brittle and end up cracking
Hi something I don’t understand I see another video you build a headers for a gaser with sch40 and on this diesel big power high egt it’s Seem like sch10 or something thin like that why ? Because I’m in diesel world and we upgrade always to thick material… thanks
The material can handle the stress in this application because the turbo is supported and braced. In a turbo Manifold situation you're usually holding up a 30+lb turbo with the Manifold, PLUS the stress of the runners glowing cherry red. Wouldn't last long. So the pipe thickness adds more physical strength than crack resistance.
Also holds a bit more heat in the runners before the turbo which is another plus.
Those aluminum heads deserve exhaust STUDS with 12 point nuts. It's only right, jut look at aircraft.. aluminum gets stud
The factor up pipe on my truck was apparently made from a 400 series stainless. Is there an easy way to tell what it is so I can get the right material for welding to it?
I'd have to see the material to know what it is, but what I'd do in this case is just use 304ss and use a 309l rod to weld them together. 309 is good for joining dissimilar stainless.
@@gleaseman Thank you!
Bung hole! 😅
What TIG machine would you suggest for someone just starting out?
Honestly the harbor freight ones aren't bad.
kinda funny that you say you only do tacks without gloves and then you welded off-camera :D (I don't care how you do it, do it how you like it)
I showed 95% of the welding lol
What brand of flap discs are you running? Also, what amps is your machine set for this type of wall.
I've come to like these ones I get locally for 40grit work: weld-ready.ca/products/pearl-greenback%E2%84%A2-zirconia-maxidisc%E2%84%A2-trimmable-flap-wheel?variant=43974162841826¤cy=CAD&srsltid=AfmBOoqmrbdykqeOMrwNyTrDRwiAshfryvCc4WcEX6yuCGnO33FvjY-w02A
that deburing tool you use, do the burs (tooling) last a long time when using it on stainless steel? noticed you use it often
Yes they do last quite a while. I use single cut burrs rather than double cut too.
Where do you like to order your parts? In Canada? 🇨🇦
I can get Vibrant parts in Canada but I have to get them through JRP which is the world's worst run company. So I usually order from the USA, and mostly from aceraceparts.com. The owner Rich is fantastic and I can have parts here literally next day.
Never wear gloves unless I'm up over 150amps welding aluminium in a closed or tight are. I'm just tough. Haha. Nah just don't have the dexterity, exspecialy my wife feeding hand. Just a habbit got from dad and it just is. So I'm all for the glove less. Rokon
How much did you charge the customer after building those beautiful headers
More than 10k, less than 20
@@gleaseman Wow I am considering following your advice on building exhaust
You suggested in your video that everlast Tig but I was wondering if you could suggest a entry model for me . Thanks
Check the description of the video I sent, there's a link to Amazon
Dang, at those temps, have you guys considered using tit-tahnium?
wooooooow nice
What do you gotta do , get a engineer degree , then it won't matter if you can wrench on it ? 😂😂
Why put egt bungs in when youre going spray enough nitrous to start a nuclear reactor 😂 what range temp do you need? 0F to the sun will do.
Does the owner of the car pay for his emissions?
Yes
Heh. Bungholes.
It's never not funny!
What kind of fabricator wears elastic skinny jeans to work?😂