Okey, this was the hard chapter of the engine building. We bought this nice stainless steel exhaust system. A piece of art it looked... a nightmare to install it proved to be...
The exhaust port diameter was 38mms, which is a nice number, equals to 1.5inches. Unfortunately the pipes on the new exhaust had 40mm outer diameter. Culture clash :-(. The ports had to be enlarged in situation, with the greatest care not to get metal dust into the engine. A pain in the back. After enlarging the ports, we had to redrill all the six holes in the flanges, as they were slightly off-centered. Nice...
Note the plugs in the air injection holes.
New problem... the mating surfaces were not skimmed after welding. The heat distorted and made the surface concave by 1mm :-o.
I skimmed them :-/... and all the other couplings...
Finally I bolted the whole together, just to find out, that the curves are not correct, thus the turbo is not at its correct situation
At this point, I intended to set fire on the whole stuff, but a young Jedi appeared in the last moment and saved the day.
I took off the turbo support plate and altered its shape. Giving the final "touches" in situation. I am affraid, that the Muffler will also need a bit of modification :-(.
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