Whats the best way to "square" a 3" round tube to fit to a T4 flange? I was thinking heat. Is there anther way?

Thanks - Ron

 

Ron, If your using mild steel it will form without heating. Start with pressing the pipe oval with a press or vise then use a blunt punch or drift punch to form it around. If your working with stainless you will need heat and as stainless heats and cools the harder it is to work with. I'll start at one end and tack weld to the flange as I form it to fit. Good Luck

 

Mallet (metal) will easily shape mild steel stuff.

 

garret has turbos coming out with vband flanges soon for the turbine inlet!

 

Yep, done it twice so far. Use a flat work-bench and the flat end of a ball-peen hammer. You can easily work it into a rectangle. If the corners aren't sharp enough, tap them from the inside with the round end of the hammer.

Mike

 

I just use a bench vise.Just did a 4" into a T-6 and it took more work with a vise,heat and some cutting.

 

Yes, Im working with mild steel. I practiced on a piece of 3" strait. It took me about 10 min. It fit perfect. Now the problem..... My 3" pipes 90* into the turbos. The 90*s donsnt come it at the perfect angle. (see pics) Any other ways to make these fit??







Thanks - Ron

 

I see SPD has some transitions for a T4 flange to 3" round. Does anyone else make these. I tryed to order from them, but they want me to download their cataloge and give them PN's. I dont live in town and my dail-up sucks and wont let me download in PDF without freezing up.

Thanks - Ron

 

If your that worried about it, just buy a T4 flange that has a 3" circular hole instead of a rectangular hole like this one:

http://bgturbokits.com/store/index.p...roducts_id=102

 

That doesn't make for a very good transition into the rectangle turbine inlet though.

 

Plenty of single turbo mustang guys have made 700+ with it. i posed that question awhile ago about the openings. look at mightymouse on here. His TTi racekit used a round opening...

 

Yea, well, there's no arguing that a round piping butting up to a rectangle opening isn't optimal.

 

Your right, but big power can be made with the round opening. I doubt it would hold his combo back.

 

There wasnt a pic of it. Anyone have a pic? Its 1/2" flange. Does it tapper from round to rectangle, or is it just a round hole into the turbo?

Thanks - Ron

 

I was taught a simple method of forming a 3" round tube into a square/rectangular opening.

First use a vice or press to compress the pipe to roughly the width of one side, preferable the long side, of the rectangle. Center the pipe over the opening and tig along the flattened sections on both long sides. Don't weld into the corneres. So now you have an oval with the two long sides welded to the flange.

Back to the vice or press and compress/crush the unwelded oval ends down to meet the short side of the rectangular opening. Weld the centers of the short side, dont' weld the corners.

Now if you're happy with how the corners line up with the flange weld it up, but usually the corners of the now rectangular pipe will need to be flared out to match the rectangular opening in the flange.

Use a ball hammer to flare/shape the tubing from the inside of the flange so that it matches up with the opening. A t-dolly works great for this, but if you don't have one of those you can clamp a piece of ~1/2" round stock in a vice an use that to hammer against so that the tubing flares out in a nice radius.

When you're done welding and forming, use a die grinder to clean up the transition and any weld slag and thats it!

I'll post pics of the one I made a few days ago for my car, when everything else is finished.

Good luck,

 

what about t6 flange single turbo im running 2 1/2 pipe from each bank to a t6 so how do you guys make a transition to that?

 

Its 1/2" thick and its just a 3" round hole. Just orient the flange anyway you want on the pipe.

 

This one shows a 2.5" hole, you want a 3" one, but you get the idea:

 

^^^ you dont want this shiotty flange unless your T4 turbine inlet is round.

 

Here is TTI's Race kit which has proved to support over 800rwhp no problem (will probably support 900-950rwhp in reality).