Jet Jockey/A4 Pilot

As you can see the TiAL wastegate is being held in the wise and the V Band flange was welded to a stainless steel piece of pipe. Both are now together being held by the clamp.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4040.jpg">


The next step was to make a hole in the collector portion of the manifold so that the S/S pipe on which the wastegate was going to be mounted could be welded onto the collector.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4041.jpg">


Here we have the wastegate installed onto the collector part of the exhaust manifold by its own S/S piping. The wastegate I'm told is at least one inch from the fender. The length of the wastegate's piping is approximately three inches only.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4042.jpg">


Try to guess what these little parts are for?

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4044.jpg">


To help you out (hint # 1) here is one of them once the product was finished.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4048.jpg">


Hint # 2. Here's the completely finished product.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4046.jpg">


Hint # 3. This may help you out a little more.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4043.jpg">


Now if you have not figured it out by now it is too late! Some of you were asking if the manifold was going to be supported in some fashion and the answer is yes. Although the 3076R with its TiAL's S/S housing is very light (only 1.5 lb heavier than a K04) we decided not to take any chances and help the tubular manifold support its weight by designing a "tripod" type support for it. Here it is prior to it being painted while test fitting was being accomplished. You can clearly see the heim joint which incorporates two spherical bearings which will allow plenty of room for expansion when things get hot.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4045.jpg">


Here it is when fully completed and painted. You can also see its attachment points on the motor.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4049.jpg">


Another angle to the whole assembly. Here we can see the two inch wastegate exhaust port going towards the back. It will at one point merge into the 3 inch downpipe.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4051.jpg">


Another angle.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4052.jpg">


Another angle showing that hood clearance is a non issue.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4053.jpg">


Further still.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4054.jpg">


And finally with the hood closed it seems there is about two inches of clearance.

<img src="http://i17.photobucket.com/albums/b79/mlab601/MichelA4055.jpg">

ScratchRob13

1" on the WG.... hope the motor mounts are stiff!

Jet Jockey/A4 Pilot

They are practically solid with barely any play.

Detroit

for the B5 s4. I feel alot more confident seeing his work on your car, that looks great.

TimD

wastegate looks pretty damn close to me. why not just make it higher?

Andy Hedin

Sweet ... keep the updates coming!

NJRickD

looks impressive!

Ram@S4-MTM

Very impressive! Consider upgrading the silicone intake hose with SS - I feel it may collapse?

Snow Trooper

haha, good work man

how have you been? long time since you last heckled me over the phone or I heckled you for that matter.

Jet Jockey/A4 Pilot

I would prefer an aluminium tube too but it may be impossible because of the space available.