The Project Pad

It's probably more like 3-5cfm. Doesn't take much, just make sure to give it time to fill up.

Purge is good when it snuffs out a lighter.

321 is better with high heat than 304, better fatigue resistance and less prone to carbide precipitation (rust) around the weldment.

They make some dual regulators for doing welding and purge off the same tank.

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You can flow more argon to begin with to clear out the air in the exhaust, but if you tape up, or fit up all your joints perfectly so there are almost no leaks other than the joint you are welding you don't need hardly any flow. Just enough to keep a slight positive pressure inside of the pipe.

hey joel, the pipe size 1.5 and 1.25" are nominal sizes, actual ID is 1.64 and 1.44" with small variations. your 1 5/8 OD tubing is probably 0.065" wall, and therefor 1/8 total wall thickness for an id of 1.5". thats really a good balanced ID size between the two pipe sizes.

as far as the backpurge, you can run it pretty low if you give it a little time to fill up, or a good bit higher if you connect, sit down and start zapping. really you just need to displace the air thats inside the tube. CFH cubic feet an hour, think about it relative to weldpiece volume. runners for manifolds dont take much time to fill but downpipes and exhausts take a lot more. less gap makes the gas requirement a lot lower.

but when you do it, weld each joint starting where the purge gas is coming into the tube, not exiting. then work your joint welds towards the purge "out" end of the tube

Thanks for the info there Tim. Since I know you've done quite a few headers, I definitely think I need to cut tacks at the collector and flange so I can fully weld some of these runners. Is heat distortion and warping a major factor doing this off of a jig?

I figure 50-65 amps is all that it will take so I shouldn't be heating it up too much.

Lastly, I noticed quite a large gap between the collector and runners, any way to minimize that? Heat and hammer?

I think I'll get some gas in the am and weld them up tomorrow.

So... some more progress! Rolled the car out for the sake of the wheel bearings and brakes and decided why not put the turbo on it.
2019-12-19_01-48-35 by Joel Francisco

The driverside manifold is welded save the collector star and a little bit more of the collector I couldn't reach. Passenger side is 1/2 done, but I ran out of gas. I'm thinking maybe I'll MIG what I can't get with the TIG? I also need to get some steel plate to weld the flanges, but no gas, no rush... It's funny. First time actually welding Stainless and the purged side came out nice and shiny while the outside is meh. Oh well. Better luck next time!! Thanks to everybody for the recommendations that got me this far!
20191220_134700 by Joel Francisco

[youtube]https://www.youtube.com/watch?v=l9D9YKZbWNY&t[/youtube]

Starting to get somewhere now and I love it haha. Probably weld everything up tomorrow and then I don't know what to do after that... I didn't think I'd make it this far.

20191229_194536 by Joel Francisco
20191229_203908 by Joel Francisco

Dagum....that’s full on “Road Warrior” style!! Last of the V8’s. Good luck with it!

The front end is on and it looks like I'll be needing a new radiator with 29"x19"x2" dimensions along with the inlet and outlets on the passenger side. I'll try and find a suitable one tomorrow, but in the meantime it's onto the intercooler piping

IMG_20200102_162518_607 by Joel Francisco
2020-01-02_04-36-34 by Joel Francisco

Got in the Dual Pass Radiator so I went ahead and made some brakes to fit in the stock location as well as the bracket for the intercooler. Coupe more small things to order in the meantime such as coupling reducers for the intake, and power steering / oil / coolant AN lines + fittings. I'm super stoked to begin the harness integration for the ECU, OBD2, and the throttle pedal; wiring fun -> fabricating not.

20200110_150700 by Joel Francisco

Been a little lazy lately. The build is starting to take a toll on me as I've been slowing down; I've been looking at R32 GTS-T's as a fun car to have in between, but we both know if that happens, I'll never finish this. So, pushing ahead. Intercooler piping is done. Engine's back out so I can make some adjustments to the engine bay. Things to do with the engine out:

-Cut/adjust the motor mount brackets to allow 2" of hockey-pucks
-Relocate ABS controller about 4" lower and make a bracket to hold it
-Reinforce subframe
-Finish welding exhaust Y-Pipe, including wastegate provision.
-Install flywheel, clutch, and pressure plate

Then I'll get the engine back in the car. From there there's not a whole lot I have to do before I can test fire:

-Run the oil lines and oil cooler
-Integrate the stock 7.1.1 ECU and harness with electronic throttle and OBD2
-Mount the throttle pedal

Then I can make some loud noises.

20200119_154426 by Joel Francisco
20200119_154442 by Joel Francisco
20200119_164735 by Joel Francisco

Hockey pucks aren't suited to the high temps in engine bays, they won't last too long. No luck with the Energy mounts for Mustangs?

PRY4SNO wrote:Hockey pucks aren't suited to the high temps in engine bays, they won't last too long. No luck with the Energy mounts for Mustangs?

I ran a pair on my 1.8T B6 for 3 years without issue. They were absolutely terrible NVH ways, but they never had an issue and I didn't run a snub mount either.

I did have heat management issues with 1.8T coils when I was running a tubular manifold, but never with the pucks.

FYI if you do go with pucks, look for the orange weighted 'training' pucks, they're a slightly softer rubber than a black puck. They'll still suck, but a little less.

Yeah hockey pucks suck as mounts, might as well be solid.

It can fit...

Easy to say until you realize the URS tie rods aren't flush with the firewall; even when your done clearing those you still have to worry about the coolant crossover pipe.

I bought 40v NA manifolds because I wanted to run the turbo there originally, but it's just way too much work and itd be a pain to work on. That's not to say it can't happen in the future, but for now deal with the retarded rhino turbo setup.

Engine mount brackets are done... 2 Offical Hockey Pucks on each side (the heat treated, stiff as hell ones).

Engines comes back out, install the clutch/flywheel/pressure plate...

Then its wiring time
20200127_163234 by Joel Francisco

At $5 a side can you really complain?! I'm mean I'm sure, I dont know why I bothered asking.... lmao

Almost ready for final install.

2020-02-06_11-59-54 by Joel Francisco
20200206_235802 by Joel Francisco

Been busy doing nothing lately. Got the engine back in with the flywheel + clutch kit and tested it to make sure I wasnt going to have the same hang-up as my first BCY 01e swap I did a year ago. Wheels are turning while moving the crank in gear and, yet stationary when out of gear... perfect.

Made a big giant to do list, and going one by one knocking everything out. Aside from making a new oil feed line to the 76mm turbo and a drain line, I'm ready to start wiring in the harness, which aside from a spanner check is the last thing on my list...

Spent all of today redoing the throttle body piping and radiator shroud clearancing among a few other stuff, and I'm able to get the front end on beautifully. [wrench][wrench]

2020-02-28_08-07-07 by Joel Francisco

Front end/engine bay is 95% sorted.

Time to start wiring the RS6 ME7.1.1 ECU and OBD2 into the C4 S6

20200306_163812 by Joel Francisco

Pulled the URS4 harness through and labeled every single wire from the chassis harness that I'll be needing. To say it was a pain is an understatement, but I'm expecting it to make my life easier when I goto plug and play everything.

Also moved the car around to make it easier to wire everything. Not fun to say the least, the next house wont have the garage on a hill lmao

20200308_162900 by Joel Francisco
20200308_200534 by Joel Francisco

First start

Damn congrats thats a big deal... Lot of work done here. You gonna put a stack on the turbo or anything ?

I'll just put a 90° off of it. Same with the wastegate. The windshield immediately fogged up when I started it so that's gotta be addressed.

I'll probably tidy up the inside now and put the interior back in.

Running... so so great!