28 replies to this topic

[TonyKL]

My vxr manifold has cracked, this is the second one to have done this. What options do I have as I dont really want to put another one on as they dont last long enough! Cheers! PS: I'm running stage 4 tuning.

[rcvaughan]

A custom fabricated tubular stainless steel jobbie?

[Crazyfrog (Fab)]

My vxr manifold has cracked, this is the second one to have done this.

What options do I have as I dont really want to put another one on as they dont last long enough!

Cheers!

PS: I'm running stage 4 tuning.

forget the xmass beer money and get a proper one

[TonyKL]

Just had a quick read and looks like the AET is recommended?

http://www.vx220.org...-To-t83595.html

Edited by TonyKL, 10 November 2009 - 02:23 PM.

[Whiteboy]

Just had a quick read and looks like the AET is recommended?

Aet only changes the impeller and the bearing though.

[TonyKL]

Just had a quick read and looks like the AET is recommended?

Aet only changes the impeller and the bearing though.

Hmm, so it would still be the same manifold :-/

Is there anything that can be done to protect the manifold?

[SteveA]

Get Courtenay to fit it and they will give you a years warranty

[TonyKL]

Get Courtenay to fit it and they will give you a years warranty

Shame, they usually just last 1 year

[cheeky_chops]

another? I am still on my original @ 37000 miles. Plenty of track (read ubber hot) action in there. so what i can work out is why?? Its either another VXR unit or a tubular from courtenay/regal. Or i hear TMS are doing one for £10...

[cheeky_chops]

seems ther are some 2/3 way options

http://regal-shop.co...r_Upgrades.html - still £2.1k + fitting! Though prob alot more reliable than OEM and more power!

And apparently courtenay are bringing out a similar product (according to AOC posts)

[Duncan VXR]

Now now boys lets get the facts correct VXR manifold is stronger than the stock VXT one AET conversion ports the manifold / increases the size of the wastegate hole You have the dblas (spelling?) manifold which is stated to be thicker and better flow (thicker casting / more equal runners etc) but silly expensive Seen a few cracked tubi manifolds in my time also Winstar covered the cracking issue some time back on a thread and don't remember it word for word but the number 3 runner gets excessivly hot and constand extreme hot / cold is like bending a paper clip I do believe good cool down / heat up of turbo helps and obviously rain on a hot manifold is never great Sorry for my delayed response been in a meeting since 11 lol Oh have 2 manifolds that are not cracked I may be able to seperate - straight swap DG

[Duncan VXR]

seems ther are some 2/3 way options

http://regal-shop.co...r_Upgrades.html - still £2.1k + fitting! Though prob alot more reliable than OEM and more power!

And apparently courtenay are bringing out a similar product (according to AOC posts)

Cheeky - CS are in final stages of testing but not a direct GT2871RS (if I remember correct) bigger cast manifold / could be the disco potato which I think is a 2871R - again cant remember specs - sorry.

This is said to go to 350bhp / 380ft/lb with internal work and making full boost at about 3.5k

Not sure I like the look of the elbow on the regal kit

DG

[cheeky_chops]

VXR manifold is stronger than the stock VXT one

Why do you say that? We took apart a z20let and a z20leh turbo (size10's knackered ones) on my kitchen table and measured them - we found zero difference in the manifold. The casting around the recirc was slightly different exterior (same inside) but inlet is nothing to do with the manifod

Unless you found some differences on your kitchen table!!?

Edited by cheeky_chops, 10 November 2009 - 04:25 PM.

[Duncan VXR]

Paul no difference in O/D as we confirmed, and do not believe the I/D is any different on the manifold but I was informed the casting material was different - other than this I cannot see any differences in fact the numbers are not much different on them either VXR turbo v's VXT turbo (excluding mani) are; Different compressor housing (as you stated) Different compressor wheel design To change from VXT spec to VXR spec is a VXR compressor housing and new wheel So not cost effective to upgrade from VXT to VXR turbo spec - to go hybrid spec you can use both as the parts are different / machines I have warped a VXR manifold but not cracked one yet - either the snapped bolt caused it or the other way round DG Oh fully stripped Steves broken tiurbo (the one you pictures) and the bearing had badly worn causing the wheel to eat the housing / bens blades and basically killed itself LOL - core looks ok to use again but housing buggered and shaft worn - looks like oil starvation caused the initial fault

[Winstar]

Winstar covered the cracking issue some time back on a thread and don't remember it word for word but the number 3 runner gets excessivly hot and constand extreme hot / cold is like bending a paper clip

It's called thermo mechanical fatigue (TMF) and that about sums it up

Not sure I like the look of the elbow on the regal kit

DG

too right that will kill the performannce of the turbine wheel

Dilbert still insist on wacking a great big lump/embossed name tag on which gives lots of section change and stress raisers that will encourage TMF

[TonyKL]

My car lives outside so I'm guessing this plays a big part in the cracking? I'm not looking for power gains, I'd be happy with less for smoother delivery, also not wanting to spend much on this guess the turbo gets hotter on stage 4 which is why standard never cracked on me

Edited by TonyKL, 10 November 2009 - 05:41 PM.

[siztenboots]

the VXT turbo ran fine , made full boost but had a squeeky manifold that would give a slightly misleading lean reading on the lamda ( causing to actually run a touch rich ) the VXR was an ebay item , sold to me as working, we replaced the oil pipe with one Duncan supplied and after fitting it would not run correct despite the install being professionally done. This was swapped then with a brand new VXR and this ran fine, it may be possible to make a Franken turbo the hot VXR manifold with a VXT cold , might as well get the dremel out and try some other stuff while at it. both actuators and solenoids should be salvageable

Edited by siztenboots, 10 November 2009 - 06:01 PM.

[cheeky_chops]

iirc the VXR unit was totally FUBAR'd - the compressor was moving so much in/out of the core it has ground a few mm off the compressor housing!!

Scoring around the centre



You can see the fins on the compressor by duncans finger bent:

[Steve B]

VXR manifold is stronger than the stock VXT one

Why do you say that? We took apart a z20let and a z20leh turbo (size10's knackered ones) on my kitchen table and measured them - we found zero difference in the manifold. The casting around the recirc was slightly different exterior (same inside) but inlet is nothing to do with the manifod

Unless you found some differences on your kitchen table!!?

oh 1st time i've seen a VX turbo manifold / turbo, weird! Turbo / manifold hybrid bastard type thing... Ditch it and put a conventional T25 footprint setup on with a garrett GT tubby? Someone must make a cast one?

[Nev]

There are shed loads of alternate exhaust manifolds on the open market, with either T25 or T30 flanges. Here are some links:

1: This chap has 2 offerings: HERE
2: Klassens Offering
3: Mani based on the S20 with a Z20LET flange
4: Liams rather expensive offering (with lifetime waranttee)

Please bear in mind that after market exhaust crack easily too. The key to reducing this is:

1) Make sure it has a fat flange (prefereably over 10 mm thick)
2) Runner stubs must be welded to the flange while the flange is bolted to a head so it cant warp with the localised heat of welding.
3) 3+ mm thick runner tubing helps
4) Bracing bar(s) to mount to engine block, this stops it being shock loaded when going over bumps and the reduces the leverage effects of 10 Kg of turbo hanging off it.
5) Ideally made of inconel steel or 321 steel, though sadly most people seem to make them out of 304 steel

Also I know quite a few semi professional welders who can make one up bespoke.

Hope that helps

Edited by Nev, 11 November 2009 - 08:31 AM.