UrS4 2.2T Avant project

[AndyP]

Best advise I got for welding ali is clean, clean and then clean some more! I have a dedicated set of stainless wire brushes just for this job, Scotchbrite is also good. I also use stainless wire wool to clean the TIG rod, then finally wipe down with acetone. You really can tell the difference, the weld pool does not appear to have as much crap in it and the weld finishes much shinier

[diesel des]

Both you guys are making lovely welds on the alloy. What sort of material thickness and current settings a.c. balance etc are you using.

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[grundey]

On aluminum I don't feel much difference gas lens or standart tig setup, maybe the weld bead looks a little more shiny with a gas lens.

Welded with standart tig setup


The same machine but with a gas lens


Most of the time I use a gas lens because it makes my torch much shorter and it is easier to get in tight spots.
On aluminium I use tight fit-up to get nice looking weld bead.

[Thuppu]

Bought a gas lens for the torch, and it feels better now. Can also keep the electrode longer, so you can see it better and can go in deeper corners. But I still will need a lot of practice to weld ally, it's really hard to get it good and nice.

[diesel des]

Nice. Tight spaces to weld in.

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[Thuppu]

Thanks. Got some weldings done today, and could fit the throttle body pipe. Quite tight fit, also the supercharger 4" inlet pipe will take some space...

[diesel des]

Nice manifold and cute cat!

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[quattro-nick]

very nice thomas,soon i'm gonna build also my own dual plenum with the same principle
i was planning to make first a hobby flow bench to see if my manifold flows different(better) than a origional,will see.

[Thuppu]

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[V6quattro]

Then i said nothing

[Thuppu]

Got info from Repo how to do it.

[V6quattro]

I'm absolute no expert in manifold fabrication but is it possible that the small opening will cause a pressure drop or a reduction for the airflow? Looks nice though!

[Majorcina]

Oh man,this looks awesome!

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[Thuppu]

Some weldings to do...

[Thuppu]

Clever one you! Well done.

Very good video here: https://www.youtube.com/watch?v=cgnB4bmodv4 But I think he's making it from 2mm aluminium which will mould easier. Made maybe 6-7 stacks that didn't turn out nicely. The most important thing is the heat.


Nick, will go with a dual plenum IM.

Edit.

Main plenum would look like this: