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+--- Thread: Turbo 240 manifolds (/showthread.php?tid=5772)
Turbo 240 manifolds - Edian727 - 08-11-2014
I am about to turbocharge my 240d. i was going to get a flange cut that covers both the intake and exhaust ports, and use tubing on out. now i read that there can be issues blowing out gaskets because of the heat on the exhaust and not as much heat on the intake. seems logical, what would be a cheap solutions around this? hate the idea of welding tubes off a cut stock manifold. also does anybody has port sizes for intake and exhaust. i assume its the same as a 617.
RE: Turbo 240 manifolds - carlitosgy6 - 08-11-2014
Hi, you can use Om617 exhaust ang intake manifolds but cutting the extra cylinder, i had done it in the past with good results if you use the kkk turbo from the later mercedes
RE: Turbo 240 manifolds - bricktron - 08-11-2014
i also would start with the 617.952 manifolds. i have a set to unload if you need them.
RE: Turbo 240 manifolds - Simpler=Better - 08-12-2014
❤utting down stock manifolds is easiest
if you want to go crazy buy my crap, although they will need some cutting to fit a 616 as well
http://www.superturbodiesel.com/std/Thread-FS-617-Blank-Exhaust-Flanges
RE: Turbo 240 manifolds - carlitosgy6 - 08-12-2014
Really the best way to go is buying simple=better crap and build a equal length header 4 to 1 and a long runner intake, but simple and faster is to use the stock Om617 manifolds and get away with it
RE: Turbo 240 manifolds - Edian727 - 08-12-2014
sweet, im ordering a set, ordered a gasket so i will see wat the difference is between the back cylinders, but im pretty sure i can use the front port for the back. also since this came out way better then expected does anyone make the intake side? i was planning on equal length and hopefully longerish, both on exhuast and intake.
RE: Turbo 240 manifolds - Simpler=Better - 08-13-2014
a stock w115 intake is already perfect, cheap, and easy to find
RE: Turbo 240 manifolds - carlitosgy6 - 08-13-2014
The na intake will work better than the turbo intake, but you will need to fab some piping, but i think your engine will be happy having an small intercooler
RE: Turbo 240 manifolds - Simpler=Better - 08-14-2014
I'll pick up a 616 gasket and play lego tonight or tomorrow. I've had a couple other requests for 616-compatible flanges
RE: Turbo 240 manifolds - Pomidori - 08-15-2014
I've got a 616 sitting on blocks that I've been trying to find turbo manifolds for.
RE: Turbo 240 manifolds - Purplecomputer - 08-15-2014
Check out my post. I think the first few pictures are the modified manifolds. Carlitosgy6 actually made them for me.
they were a perfect fit.
I dont think I would trust this simpler=better guy :p
RE: Turbo 240 manifolds - Simpler=Better - 08-15-2014
(08-15-2014, 03:16 PM)Purplecomputer Check out my post. I think the first few pictures are the modified manifolds. Carlitosgy6 actually made them for me.
they were a perfect fit.
I dont think I would trust this simpler=better guy :p
Nah man, I just send you a box-o-parts
You're still on your own for standoffs (cut down 1/2" pipe) and a turbo flange (depends on your application)
RE: Turbo 240 manifolds - Pomidori - 08-15-2014
(08-15-2014, 03:16 PM)Purplecomputer Check out my post. I think the first few pictures are the modified manifolds. Carlitosgy6 actually made them for me.
they were a perfect fit.
I dont think I would trust this simpler=better guy :p
I've been following that thread for a year and it is my inspiration for doing this to my 240. I'm glad you decided to keep your Benz even though it's been so much trouble, you rock! Also, how can I contact him? I considered welding them myself but I would probably botch the job
RE: Turbo 240 manifolds - Edian727 - 08-15-2014
sweet. I'd really like to build my own intake though, got this idea in my head. got a turbo off a saab at pull and save, nice little t3, 42 trim intake not sure on exhaust, and the tubing 4 it too. its got 1 big alluminum piece that says turbo im gonna cut a bend out of and use. might just get a w115 intake though bet it'll be cheaper. i also have a small intercooler im going to use, and hopefully i can afford a ALDA after all my piping.
But this might get put on hold for a couple months as i might get a Thermal Arc 190. great ass welder but it'll eat all my extra dollars.
RE: Turbo 240 manifolds - Edian727 - 08-16-2014
Welders out, guy wont come down to my price and the GF wont let me spend more. just sticking with using my buddies machine.
RE: Turbo 240 manifolds - carlitosgy6 - 08-17-2014
The saab turbo is a little big for a 240
RE: Turbo 240 manifolds - Simpler=Better - 08-18-2014
w115 240D intakes are like $40 on eb*y, save yourself the trouble.
As for welding, any cheap lincoln or miller stick(arc) welder is fine. The trick it prep, prep, prep, good fitment, prep, prep, and making sure you have clean prepped surfaces. Watch some videos on youtuube on welding, it's really not that hard once you get the hang of it. Practic on similar-sized pieces of scrap to get practice.
Aluminum is tricky, look into "white metal rods" or "alladin rods" you can braze alum with these and a MAPP gas torch (found at home dep*t)
RE: Turbo 240 manifolds - MFSuper90 - 08-18-2014
If you are not familiar with welding, mock it up how you want it by tacking it together, then find a friend that is a good welder to weld it all together.
Preferably leave the manifold on a spare head or make a jig while your welding it, if not it will warp and you will have an exhaust leak that will be as annoying as a 5.4L in a F-150.
But then again, if you have a friend that's a professional welder that is very intelligent he would probably know how to weld it without it warping bad enough to matter. Or you can have it machined if it warps
Just sayin, cause everyone hates exhaust leaks
RE: Turbo 240 manifolds - Edian727 - 08-18-2014
I can weld. just dont have a welder. my old boss had a thermal arc 190 and it was great. but regardless, i am going to go with the w115 intake cuz of money. I have a friend who can TIG so im going to have him weld my alluminum piece
. might look into brazing though never done that before sounds fun. just waitin right now to hear about exhuast flanges and my next check for piping.
RE: Turbo 240 manifolds - sassparilla_kid - 08-19-2014
I plan on welding up a fancy octopus violating turbo looking set using simpler=better's flanges (okay maybe not that fancy) so I can turbo my w115 240D, hopefully I don't make things go boom too loud because rebuilds cost moneys
Also, I plan on doing it all the gentlemanly way with an oxy/acetylene torch
RE: Turbo 240 manifolds - carlitosgy6 - 08-20-2014
Sassparilla go to harbor freight and get a cheap mig, acetylene is so expensive these days mig got cheaper
RE: Turbo 240 manifolds - Edian727 - 08-25-2014
yea mig is the way to go, that would drive me crazy trying to do it all with oxy/acetalyne. flanges are coming
. sold my jeep so i have a little money to play with now, thank god cuz stuff is expensive. The turbo is actually off a saab 99. big funky looking external wastegate on it. I like just hope it works right.
this part was hooked in exhaust and acuates the gate i think.
and this run to the intake side and not sure wat it does, i read somewere that it acts like a spring holds it shuit but that doesnt seem right as vaccum in the take would open the wastegate.
seen better here
i also got my gauge in the mail, isspro turbocator(thats wat they cal it), boost and egt, came with probe, and evrything needed to hook it up, gonna cut a big hole in my non-working clock and mount i there
and the piece in gonna use it says turbo!
RE: Turbo 240 manifolds - carlitosgy6 - 08-25-2014
If is from a 99 probably is a t25,good match!!
RE: Turbo 240 manifolds - sassparilla_kid - 08-26-2014
What are you guys talking about torch is awesome! Haha I do have access to mig though and could probably get my hands on a tig too, or I might buy one, Idk they're like the same price as superpump and turbo upgrade
RE: Turbo 240 manifolds - raysorenson - 08-26-2014
I love my Eastwood Tig. Great bang for the buck.
RE: Turbo 240 manifolds - yankneck696 - 08-28-2014
That looks more like an EGR valve to me.
Ed
RE: Turbo 240 manifolds - Tito - 08-29-2014
It's after the turbine so it's not a egr valve. Just a huge waste gate. I've got 2 Porsches 944 turbo's standing at my job an they both have these huge wastegates.
RE: Turbo 240 manifolds - Edian727 - 08-29-2014
Got flanges today, they look excellent and i cant wait to weld to em
. Also retrieved the intercooler, out of a mazda millenia with the supercharger 2.3 v6. 1.5" id inlet and outlet, o-ring seal, 4.5" wide, 2.5" thick, and 8.5 inch long core, total is 16.25" long.
Turbo is a t3. they changed to the t3 for 79-80, and the donor was a 80. also flanges matches t3. if its to big then i need more fuel right? part of the plan. I plan on getting my spare injectors rebuilt with 315 nozzles, and i have a spare pump so im not afraid to mess with it. at any rate it will be better then the stock 617a turbo but only a little, .45 for 617 and .42 for the saab, iirc.
I found parts for the wastegate so im gonna rebuild it and use it, i like it. it looks kinda retro. Didnt know porsche used them, its the first and only stock external i've seen. that's one fo the reasons i grabbed it and want to use it.
RE: Turbo 240 manifolds - sassparilla_kid - 08-29-2014
My flanges came in today too! With a bonus surprise in the box!