Badger equal length 1.8t mani for ibiza revealed

Discussion in 'Badger5' started by badger5, Aug 24, 2006.

  1. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    Here's a sneak preview of the new equal length tubular exhaust manifold we have been working on, for Project Ibiza Racecar.

    We have partnered up with a fabricator who builds manifolds and systems for Red Bull Racing, WRC teams etc... Top Notch and UK Manufactured.

    As you will see, the construction is one the highest quality standards you will see in the welding & design.

    The spec pictured is for my own ibiza, so runs and IHI flanged outlet. This will be available also as T3 Flanged as req'd for garrett fitment etc.

    Pricing is TBC, as some options of ceramic coatings, fully annealing, additional EGT bosses, pre & post turbine, multiple lambda bosses for mapping etc.

    Fitting onto my ibiza over the next few days. Trial fitment went well.

    New Stainless Steel 1.8T Equal Length Manifold-Preview as to be running on my ibiza racecar shortly.

    Genuine Equal length within 1/2" (18.5" runners)
    High Quality TIG welded, back purged, jigged assembly, featuring narrow angle merge collector.

    Lightweight construction, not made from heavy wall pipe fittings, built by a fabricator who makes WRC team systems, and Red Bull Racing development manifolds. Extremely high quality, British made manifold.

    Pictures below of dummy setup on a spare cylinder head.
    Fitted onto my ibiza this evening

    Enjoy
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    Top Mounted as you can see for ease of fitment, access to all fittings, improved flow for DP and inlet, (not stuck by gear selector cables)

    [​IMG]
    Full Flow area DP in 3"


    [​IMG]
    [​IMG]
    [​IMG]
    New Hybrid Turbo mounted onto manifold. Flanged in picture as IHI, but also T3 flange as req'd to suit GT30/35 units. This turbo going on mine is physically larger than GT30R.

    This is a preview. There will be some updates on this for upper support brace.

    Prices for production customer units will follow.
    DP modification due on Mon/Tues on mine, production tooling jigs and fixtures have been made to replicate this.

    Coming soon will also be an charge air pipework setup and intercooler also, from the same fabricator. WRC spec components & design.
     
  2. TurbTech Forum Junkie

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    WOW that is some pretty amazing work there but just one question . . . . . .


    . . . . . . would he make me one for my 16v? I'll buy him a drink!
     
  3. Dub20vt Forum Member

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    Wow!

    that's impressive stuff bill.

    be interesting to see some prices once he's ready to produce more.
     
  4. Seraph Banned

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  5. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    aye.. in exchange for an amount of money I'm sure they would.
     
  6. Bundles Forum Junkie

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    Oh man, that's pure manifold porn that is!

    Nice to see they have not followed the impreza method for the IHI wastegate gasses, the stock scooby downpipe flange has a flat face that leads into the normal downpipe, the wastegate gases come out of the turbo and slam into the flat face, they then have to turn 90 degrees, along a few inches and then 90 degrees again down the downpipe, it plainly sucks.

    The only manifold i have seen before that looks anything like this one is the manifold off of a WRC Focus :)
     
  7. stephcasscar Paid Member Paid Member

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    Ive bought a plate from germany that will enable that manifold to be used on a 16v Head ;)


    That a cracking manifold bill :clap:
     
  8. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    Strange you should say that ;)

    They do WRC car's amongst some F1 team stuff too.
     
  9. King Kwik

    King Kwik Forum Member

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    Nice.
    I know how much work goes into something like that.
    Bill, will there be any bracing or supports ?

    Lee
     
  10. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    yep.
    Top brace for turbo and I think I will add a brace for DP mid section. Torn between making the DP a 2 piece affair although it surprisingly fits in from the top even with turbo in situ.
     
  11. vrbanana Forum Junkie

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    nice, i'll have 2 of them, one for me and one for the mate... 10.00 in post Bill and keep the change :lol: :lol:

    come on, sort a price out, then all we need is you to test them on the track
     
  12. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    its going to be tested alright..
    should be fun... and I am fully expecting to be scared silly in the ibiza next drive...
    EAK!
     
  13. danmoody Forum Member

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    that is the works, how much is this set up to buy [:^(]
     
  14. Lee-GTi Forum Member

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    Thats AWESOME!!!!!! Some nice welding!!!
     
  15. ViCk Forum Member

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    Hardcore ! :thumbup:

    Love it mate !
     
  16. ianb Forum Member

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    I want one!!

    Ian
     
  17. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    and available in RHD ;)

    all it takes is some sheckles and you too can have one..
    nice and easy to fit.
    no nasty compromises for pipework in or out being top mount.
     
  18. jc.. Forum Member

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    what exactly is back purging?
     
  19. badger5

    badger5 Club GTI Sponsor and Supporter Trader

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    purging the internals of the pipe with the inert welding gas, so no oxidisation can occur unside where you cant see it.
    also welding in a bubble containing inert gas gets you the same effect externally too. (high usage of gas mind you)

    this is what these guys have to do with their F1 systems, WRC etc and the like.
     
  20. nass Forum Member

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    Hey Bill

    Do you think your man could make me a 16v turbo manifold for a left hand drive Rallye
     

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