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Thread: John's EZ36R H6 818R Build

  1. #561
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    Nice work

  2. #562

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    I bet you are enjoying doing that tig work. I do myself. Your work looks super.

  3. #563
    Senior Member Hobby Racer's Avatar
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    Quote Originally Posted by Mitch Wright View Post
    Nice work
    Quote Originally Posted by aquillen View Post
    I bet you are enjoying doing that tig work. I do myself. Your work looks super.
    Thanks guys. I enjoy learning new skills. And while I'm sure the welds would look nicer if done by a professional, I take pride in being able to say I built everything on my car myself. And as Lance said, the only way to get better at welding is to weld more
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  5. #564
    Senior Member Hobby Racer's Avatar
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    More progress. I welded the tubes into the flange on the side that bolts to the cylinder head. The tube on the far right looks beautiful, almost like it was machined into the flange. The other two not as nice. The nice tube was flush with the flange and the other two were sunken down. It was much more difficult to get the torch in at the correct angle on those and I had a hard time positioning the piece while welding. But in the end all the pipes are fully sealed and that's what really matters.

    IMG_20190226_171312.jpg

    I also got the merge pyramids welded in place. These seal off the center section of the pipes so there are no leaks and provide a smooth transition for the exhaust gas to go from individual pipes into a single larger pipe.

    IMG_20190226_171331.jpg
    Last edited by Hobby Racer; 02-26-2019 at 06:57 PM.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  7. #565
    Senior Member Hobby Racer's Avatar
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    Headers are done!

    Finished welding up the headers today. Man it feels great to have accomplished that. I am very pleased with the way they turned out. I am also glad I designed them in CAD first. They fit exactly like the CAD model predicts.



    For those interested here is a picture showing a full penetration weld of a primary tube to the thick flange where I used the Solar Flux instead of back purging. I chipped away half of the glass like coating left behind so you can see underneath. It does a great job, no oxidation.

    IMG_20190227_104253.jpg

    After I was finished, there was some slight warping on the header flange so I leveled it by placing adhesive backed sandpaper on the top of my cast iron table saw (which is ground very flat). By running the flange back and forth a few hundred times, I'm not kidding either, the flanges are now dead flat.

    IMG_20190227_105327.jpg

    I needed to make a handy jig to hold the assembly vertically so I could weld on the collectors. Notice the back purge setup for these welds.

    IMG_20190227_145953.jpg

    Here are some more pictures of the finished product.

    IMG_20190227_164137.jpg IMG_20190227_164327.jpg IMG_20190227_102932.jpg IMG_20190227_164203.jpg
    IMG_20190227_164255.jpg
    Last edited by Hobby Racer; 03-02-2019 at 04:01 PM.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  9. #566
    Senior Member Hobby Racer's Avatar
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    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

  10. #567
    Senior Member Hobby Racer's Avatar
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    Next I will be adding in the resonators and tail pipes. I bought these shiny ones, aren't they pretty

    IMG_20190227_164637.jpg IMG_20190227_164644.jpg
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  12. #568
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    Your headers turned out very nice! You have hidden skills. I wish my first weld job looked that nice!

  13. #569
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    Sharp

  14. #570
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    beautiful
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

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    Outstanding work!

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    Great job John, your decision to mod the frame rather than moving the engine back an inch really makes this routing of the headers much easier. My dicision to move the engine back may prove to be problematic. I also only raised the engine 1/2" I'll probably raise it another 1/2" to an inch like you did.

  17. #573
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    Quote Originally Posted by flynntuna View Post
    Great job John, your decision to mod the frame rather than moving the engine back an inch really makes this routing of the headers much easier. My dicision to move the engine back may prove to be problematic. I also only raised the engine 1/2" I'll probably raise it another 1/2" to an inch like you did.
    Modifying the frame was definitely a good choice. It has made many of my other modification easier.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

  18. #574
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    This looks awesome. I wish I could weld like that.

  19. #575

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    Your work makes me feel good just looking at it.

  20. #576
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    Quote Originally Posted by Rob T View Post
    This looks awesome. I wish I could weld like that.
    Heck, I couldn't weld like that a month ago. All it takes is determination and practice.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  22. #577
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    Great work! Really makes me want to get a TIG welder.

  23. #578
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    Beautiful, can’t wait to hear it.

  24. #579
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    Nice work On the 33 there is very little room! It is fun to build your own parts, welder, grinder, time = new one-off parts!

  25. #580
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    Exhaust pipes done

    Finished the exhaust out the back finally. I made some neat exhaust hangers that incorporate into the u-bolt clamps to hold up the back of the mufflers. I wanted some type of mounting that would have some give and flex when the motor vibrates and twists. The nice part is the hangers are threaded at the top so I can adjust the muffler height very precisely.

    IMG_20190311_124805.jpg IMG_20190311_124349.jpg

    I had to relocate my wing mount uprights and my transmission pump and my oil catch can, but it was worth it!

    IMG_20190311_124401.jpg IMG_20190311_124239.jpg IMG_20190311_124155.jpg IMG_20190311_124229.jpg
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  27. #581
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    Two thumbs up now lets hear a sound clip.
    Last edited by Mitch Wright; 03-11-2019 at 04:22 PM.

  28. #582
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    Was thinking bungee cords. Yours is nicer. Looking good!

  29. #583
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    Ooh.. it sounds nice.

    I'll post a short clip after I get the idle working.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  31. #584
    Senior Member AZPete's Avatar
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    beautiful work. Clever design.
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  32. #585
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    Sound Clip for New Headers

    Here is a short clip with the new headers. My phone camera gives the exhaust a raspy sound that you do not detect when standing near it.

    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  34. #586
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    Sounds great and very unexpected with the idle tone!
    Gen 3 Type 65 Coupe builder

  35. #587
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    Very cool!!

  36. #588
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    wow!!!

  37. #589
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    Cold Air Intake

    Getting close to being finished with the winter modifications this year. One of the last things on my list was to make a cold air intake that rams cool ambient air into the intake from the passenger side vent. I ended up going with an inline air box (its a cylinder really) that has a cone filter inside.



    I started by bending up a square tube the size of my intake adapter ~ 4 1/2" out of some scrap aluminum sheet. Then I needed to sculpt it to fit the side sail as best I could. That was quite hard, trying to fit a square tube to the multi curved inside body. I had to angle it up enough to clear the inner fender but not so much that it interfered with the rear deck lid. It was a very close fit.

    IMG_20190323_110823.jpg IMG_20190323_110845.jpg

    I then used resin and mat to bond the aluminum scoop to the inner fender in three places.

    IMG_20190323_120732.jpg IMG_20190323_144944.jpg

    After the resin hardened I reassembled the body and checked for fitment. I love the way it came out and it should give the engine plenty of cool air, especially at speed!

    IMG_20190323_144957.jpgIMG_20190323_145027.jpgIMG_20190323_145043.jpgIMG_20190323_145816.jpg
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  39. #590
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    Very nice work!
    Wayne Presley www.verycoolparts.com
    Xterminator 705 RWHP supercharged 4.6 DOHC with twin turbos

  40. #591
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    Front wheel mesh screens

    Back in a previous post, I opened up the gap between the leading edge of the doors and the back of the front fenders to allow high pressure air to exit the wheel wells and get more air to flow along the body and into the rear scoops. The enlarged openings work great, but I get tons of debris and stones flying out and blasting my paint. A while back I purchased some nice aluminum hex mesh screen and now I have finally gotten around to fabricating some front wheel screens. I think they are a nice touch and will hopefully prolong my paint job.



    Passenger side with the door off.

    IMG_20190324_165207.jpg IMG_20190324_165228.jpg IMG_20190324_165247.jpg

    Driver's side with the door on.

    IMG_20190324_182302.jpg IMG_20190324_182308.jpg IMG_20190324_182512.jpg IMG_20190324_182523.jpg
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  42. #592
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    John, you can also add some Helicopter Blade Tape to the leading edge of the door. (tough stuff looks like a clear bra) let me know if you would like some, I can send it over.
    Last edited by Mitch Wright; 03-25-2019 at 08:30 AM.

  43. #593
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    Quote Originally Posted by Mitch Wright View Post
    John, you can also add some Helicopter Blade Tape to the leading edge of the door. (tough stuff looks like a clear bra) let me know if you would lie some, I can send it over.
    Thanks Mitch. I actually have XPel clear paint protection on the leading edge already. It works well but the added protection of the mesh is good for the large / sharp stones.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  45. #594
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    Pay It Forward

    Since my new headers are complete, if anyone wants a set of custom EZ30R or EZ36 headers for their 818 build, PM me. You can use them as is or as a starting point for your own design. I would just need $ for shipping.

    IMG_20171127_153502.jpg

    Post showing the finished headers.
    Last edited by Hobby Racer; 03-25-2019 at 07:06 PM.
    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

  46. #595
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    Pm sent

  47. #596
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    Headers Wrapped

    I decided to try thermal wrap on my new stainless steel headers. I figured since they shouldn't rust the wrap should be ok instead of the very pricey ceramic coating I used on my first set of mild steel headers. Some tips for others planning to wrap their exhaust.

    • Use the expensive wrap from DEI. There is a reason they are the best.
    • Get the Titanium Lava Rock wrap. It doesn't itch and its very pliable without having to wet it.
    • Use safety wire to tie off the wrap. It's easier and you can get it tighter than those dam straps they give you.


    MK3.1 Roadster completed 2011
    818R built with EZ36R H6 completed 2018
    818R rebuild with a JDM Honda K24A

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  49. #597
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    From a purely aesthetic non functional stand point those fender openings look awesome. I would do that to my car even if they served no purpose. Headers look good too.

  50. #598
    Tazio Nuvolari wannabe Scargo's Avatar
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    Quote Originally Posted by Hobby Racer View Post
    I decided to try thermal wrap on my new stainless steel headers. I figured since they shouldn't rust the wrap should be ok instead of the very pricey ceramic coating I used on my first set of mild steel headers. Some tips for others planning to wrap their exhaust.

    • Use the expensive wrap from DEI. There is a reason they are the best.
    • Get the Titanium Lava Rock wrap. It doesn't itch and its very pliable without having to wet it.
    • Use safety wire to tie off the wrap. It's easier and you can get it tighter than those dam straps they give you.
    • I agree in all aspects (and have used the stuff for years) but the downside is the wrap can hold oils and even antifreeze, which will burn.
      A friend had enough oil related fires that he went to Heatshield products. Available through Summit. Though pricey, they last a long time. There are several other brands with similar products.

  51. #599
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    Quote Originally Posted by Scargo View Post
    • I agree in all aspects (and have used the stuff for years) but the downside is the wrap can hold oils and even antifreeze, which will burn.
      A friend had enough oil related fires that he went to Heatshield products. Available through Summit. Though pricey, they last a long time. There are several other brands with similar products.
    I've used the Heatshield Products stuff as well. It's pretty awesome for heat retention. It can be removed and reinstalled easily. However, it still a fiberglass mat type material on the inside and soaks up fluids.

  52. #600
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    I am amazed at the incredible fabrication work being applied to these cars. I guess I should not be surprised though, its a great package so it is going to attract some very talented people. Awesome work Hobby.

    ss

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