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Some of your message is cut-off so I can't read the whole queston, I'll answer what I can read... I have about 15 in use with this flange cut design, none have reported any problems with it. The end of the cut is clearly a stress focal point where cracking could occur, but the flange is held...

Here is a pipe version with the flange plasma cut. this is the "log style" one, I also make an equal lenght one using the same material and methods.

I actuay do something very similar to your suggestion, I just had not completed that manifld in the picture. I fully complete the manifold, and then cut the space between each runner on the flange with a plasma, leaving just 1/2"-3/4" un-cut. that remianing uncut portion retains the position...

I use solarflux type B, it goes on as a paste on the back side of the weld (inside the tube in this case) and hardens into a glass/ceramic like substance when welded. It shields the molten weld pool on the back of the weld from any/all air, and the glass/ceramic substance supports the weld from...

What is the OD and length/QTY of tubing you have? What I'm looking for is 1-3/4" OD in 16 gage, but I could probalby use 18 gage and not loose much strength. I'll have to ask my bender if he can do that ID, his setup is for 16 gage, but I suspect the 18 gage will bend OK on the 16 gage...

Thakns for the distinction NickE, this product is something that has to look good in service, it's an aftermarket performance item that people would want to show off. I understand there is a distinction between minor surface rust vs severe structural damaging corrosion. In my aplication any...

I've heard some 4NN allowys are prone to rust with temp, 409 in perticular. Also, my EGT's after the turbo are ~ 900-1100, but up to 1400+ before it. part of a turbos "free" energy comes from the energy in the temp conversion. Is 439 a commercialy available grade? I have not seen it.

This is what the 321 ss version looks like: http://webpages.charter.net/catsamuel/DCP01017.JPG http://webpages.charter.net/catsamuel/DCP01022.JPG the runners are tuned in length to this motors power peak, and all 4 runners are within 3% of equal length.

Yes, I too belive it is the thermal effects and unavoidable vibrations that kill these, not the gasses present. Coatings that are common in ths aplication can be as much as $200 per item, so it's pretty cost-prohibitive. any tips on what coatings are available? the only one I know of (jet...

Yes, I am in a bit of a corner here, I can hardly sell them if I use a propper product like 321 SS or 625 inconel because cost is a major factor in my consumers decision making process. Also, the 321 and 625 are terribly difficult to source and I use a lot of material in the product. Many of...

For the record, I am NOT a metalurgist, just a hobbiest that tries to understand things with research and "good" advice. I have been fabricating automotive turbo exhaust manifolds for some time using .065" wall 304 and 321 ,and some inconel 625 tube, and now similar models using sch 10 pipe of...