Building Stainless Steel Outlet for Hydra HP650's

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mikeseli

Specialist
May 23, 2017
81
How much clearance do you have between the front manifold and the stainless 1.75" primary outlet pipe? will you be able to install that heatshield now?
It's looking great, nice work.
 
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fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
How much clearance do you have between the front manifold and the stainless 1.75" primary outlet pipe? will you be able to install that heatshield now?
It's looking great, nice work.
Good question. We've not firmed up the front tube location, and need to check clearance with the shield. I'll make sure I cover that on the next work day.

Filippo
 

fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
Okay a bit more progress in the shop yesterday. Worked on getting final fitting sorted out relative to the Hydra shield. From doing this I figured out that the front turbo was not clocked quite right. So I work that until the outlet reasonably cleared the shield, while maintaining about 0.040" clearance from the wastegate to the block. We have some minor mods to make to the shield where there is contact in various places. Neither Omar or I could figure out why ... I chalk it up to minor assembly variations ... no worries, they are easy adaptations.

So everything at this point is tacked in place, minus the connecting pipe for the outlet to charge air coupler pipe that goes to the FMIC. I need to grind angles on those two pipes to make the proper angle, so those went back with me to do at my shop. I suspect next week we'll have it together, and then @[email protected] will backfill the pipe with Argon gas and TIG all the seams.

Filippo

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Shield clearance work:

front clock shield.jpg . front clock.jpg . shield clearance 2.jpg . shield clearance 3.jpg . shield clearance.jpg .

Modification marks once turbo was clocked:

shield clearance cut 1.jpg . shield clearance cut 2.jpg . shield clearance cut 3.jpg

Sizing turbo couplers:

cut coupler.jpg
 
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Rob09msport

Captain
Oct 28, 2017
1,316
Monroe CT
Okay a bit more progress in the shop yesterday. Worked on getting final fitting sorted out relative to the Hydra shield. From doing this I figured out that the front turbo was not clocked quite right. So I work that until the outlet reasonably cleared the shield, while maintaining about 0.040" clearance from the wastegate to the block. We have some minor mods to make to the shield where there is contact in various places. Neither Omar or I could figure out why ... I chalk it up to minor assembly variations ... no worries, they are easy adaptations.

So everything at this point is tacked in place, minus the connecting pipe for the outlet to charge air coupler pipe that goes to the FMIC. I need to grind angles on those two pipes to make the proper angle, so those went back with me to do at my shop. I suspect next week we'll have it together, and then Barry will backfill the pipe with Argon gas and TIG all the seams.

Filippo

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View attachment 29584

Shield clearance work:

View attachment 29585 . View attachment 29586 . View attachment 29587 . View attachment 29588 . View attachment 29589 .

Modification marks once turbo was clocked:

View attachment 29590 . View attachment 29591 . View attachment 29592

Sizing turbo couplers:

View attachment 29593
Im glad you said that I think people are getting results all over because the turbos are all clocked slightly different also when I was trying with vrsf outlets I modified corner of heat shield .
 

fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
Im glad you said that I think people are getting results all over because the turbos are all clocked slightly different also when I was trying with vrsf outlets I modified corner of heat shield .
My lock nut was not tight on the front turbo band clamp, when I loosened it up to re clock. Anyway moving the turbos around some may help with issues mounting outlets. I never understood why they don't work with outlets.

Filippo
 
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fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
Modified the Hydra heat shield for clearance in a few places, and smoothed the radius at the coolant pipe relief. Also ground two 6mm angles on the splay output which will join the exit pipe to the FMIC. I was 12mm off square so this splits the difference. The segment pipe will get cut short and then beaded for silicone tubing. Next Tuesday we plan to do final fit, and get this all welded up. We'll tack a small stainless triangle on the edge I ground off - that's for better clearance on the front turbo outlet pipe.

Filippo

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ShocknAwe

Lieutenant
Jan 24, 2018
682
SC
Gorgeous. I like that you are taking the upper path for the piping instead of going low as well.
 

fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
Alright, today was the day to finish up. We had the final snout piece to make, where the collector goes to a beaded snout to the FMIC. I had ground both the collector and snout @ 6mm angle to change the pipe direction for alignment while maintaining an equivalent oval on both pieces for the join. @[email protected] is the man behind the mask. We then shortened the rear tubing a bit, and got all the hump connector sized up.


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fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
With everything fit, tacked up, and checked for clearance, we plugged the ends with aluminum foil and back-filled the tubing with Argon gas. @[email protected] then welded all seams. Outlets in T304 came in around 3.5 lbs. Not bad for an industrial solution that handles heat differentials about as well as it is going to get.

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fmorelli

Colonel
Staff member
Aug 11, 2017
2,303
Virginia
Finally a video walk around:


It was a fair bit of work to fabricate this set, mostly for two reasons: first time around of course, and the second reason being that we spent a fair bit of time making (sizing, joining) the tubing snouts which meet the turbo outlets. We have some additional tubing to make a set for the 3DM Motorsport track car. I believe it would take Barry and I one full day to make a set of these for that car, given what we know now.

For those having issues fitting outlets to the Hydra turbos, I found a number of nuts that were not tight. Check your turbo clocking and sort that out relative to getting outlets attached. Also, check the nuts on the back fo the wastegate - mine were not tight, nor was the band clamp nut on the front turbo.

Filippo
 
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