My First Compound Kit I Fabbed. Can't Wait to Finish the Rest of the Piping!

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BarnBuiltBeaters@reddit (OP)

I can't lie, I stared at it for about 20 minutes yesterday. Hard to believe i built that! Can't wait to paint the turbos to match the engine in the next few days!

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I can't recommend enough that you consider a coating like Ceracote for your turbos. It is a bit difficult/different to apply, but it works really well at creating a thermal barrier, both ways, as do a lot of ceramic coatings. I recommend Cerakote mostly because of its toughness, and that you can basically get it in any colour.

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BarnBuiltBeaters@reddit (OP)

One step ahead of you. The tan and black you see on the turbo/engine is cerakote good for 2000°F just haven't gotten that far. Hopefully tonight I can get a coat down

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IronGigant@reddit

Niiiice.

Let me guess, Tan on the impeller/cold side, and black on the turbine/hot side?

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BarnBuiltBeaters@reddit (OP)

Yessir! Should look decent. Contemplating painting the V-band clamps too just not sure how well they would hold up to a socket

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IronGigant@reddit

For V-bands, media-blast the exterior surfaces. It really helps.

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BarnBuiltBeaters@reddit (OP)

What about the nut? Will cerakote it hold up when tightening?

Not sure if that's an option for me as I dont have a media blaster and can't really justify it yet

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IronGigant@reddit

Depending on where you live, there's probably a shop that can do small-batch orders of parts, or even someone offering services on Marketplace. It's not a super complicated process.

I'd remove the nut and thread it onto a sacrificial bolt of the same size and pitch, and tape off the treads of the T-bolt on the clamp. Use a fine media, and then do a couple coats of CK, first a light coat, then a heavy coat.

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BarnBuiltBeaters@reddit (OP)

Thanks! I actually never thought of that. I've media blasted before at a previous company. I don't have the equipment nor does my current work place

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IronGigant@reddit

They're messy, they use all your shop air, and they're slow to use, so not having on in the home shop is perfectly fine.

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shift-bricks-garage@reddit

It's truly a work of Art. I just got power set up in a new house. Haven't so much as tack welded anything in over 15 years. Gonna use my cars exhaust , body and what not to use as my test subjects. Definitely loving pie cuts for looks and also because I'm not buying any benders very soon.

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BarnBuiltBeaters@reddit (OP)

Thank you! I'm insanely proud of it! Pie cuts looked nice but it is a lot of welding! Good luck welding it comes back fast!

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shift-bricks-garage@reddit

Thank you! I'm gonna take a 1:1 class to get caught up with mig. Then again with tig.

My buddy and I were thinking about compound turboing his rally car. Did you reference anywhere specific to decide the placement and details?

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BarnBuiltBeaters@reddit (OP)

Best thing to do is practice practice practice and watch some YT videos.

Placement, just what I thought would look cool. I wanted to see both turbos as a lot of kits do over/under rather than side/side. For sizing this is a pretty standard setup a lot of people use so I'm just copying. S363 with S475. Should be good for +800hp.

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badburb@reddit

12v f100?!?

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BarnBuiltBeaters@reddit (OP)

It's a bit of a frankentruck but it's what I wanted. 1978 F250 body swapped onto a 2018 Ram 2500 chassis. 12V Cummins swapped with a Ford 6.0L ZF6 manual transmission. I designed and fabricated an adapter to use a tesla electric I-Booster for brakes. Trying to make the truck unique, make it ride better, and of course more power.

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fiddlythingsATX@reddit

A standard cab dentside fit on the Ram?? Tell me more!

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BarnBuiltBeaters@reddit (OP)

I ended up cutting the chassis in half, cutting out 3ft, and welding the chassis back together. Had to make all new body mounts too obviously! Was my first fabrication project haha!

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fiddlythingsATX@reddit

Impressive and super cool!

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DeepSeaDork@reddit

I have to say that's one of the most unique builds I've ever seen. Must ride like a cloud on that chassis, has a hell of a 12V, and a great body. Nice build.

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BarnBuiltBeaters@reddit (OP)

Thanks! It's still just a roller. The engine has no internals. The body needs paint, brakes need to be plumbed and replaced, hole in the firewall, on and on and on. Slowly it's getting put together!

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DeepSeaDork@reddit

That's a ton of work, but a hell of an imagination to think of it and ambition to pull it off. I look forward to seeing the build, it really is an awesome start.

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BarnBuiltBeaters@reddit (OP)

Loads of work for sure! If you are interested I have a YouTube channel same as my handle here.

I enjoy taking pieces of vehicles and making them work together. I think going forward everything will be pretty standard until I get to the interior. I want to make it a bit more modern yet keep the classic feel of it.

Thanks for the compliments!

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eddirrrrr@reddit

What a random assortment of parts that's awesome lol

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BarnBuiltBeaters@reddit (OP)

It really is! So it started off just as a regular 78 F250. I thought it'd be a neat idea to have a modern chassis under to improve a lot of short comings of the original. I wanted a 2018+ Ram 2500 chassis due to coil suspension in all the corners, figured it'd ride better. This was 2020, figured there was no way I'd find one for a price I could afford. Well...turns out I found one. 12V I picked up from a friend. I sort of wanted to do a diesel from the start and he sold it to me cheap. Ford ZF6 trans is a common swap since it'll hold more power than manual dodge trans. Electric brake booster I thought was neat. I've seen some people do it and my vacuum booster won't work with a diesel. Wonder what's next lol

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SpaceTurtle917@reddit

I made this equation for pie cuts a while ago.

Just enter your bend angle (S), number of pies you want to achieve that (n), you’ll get A, which is the angle you need to cut the pies at.

Enter in the external bend radius R and you’ll get the outside length to cut each pie. Likewise if you enter R as the internal bend radius you’ll get the inside length to cut each pie.

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AngryScottish@reddit

What's the benefit of pie cuts over mandrel bends?

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SpaceTurtle917@reddit

Came in very handy for this tight fit oval tube downpipe. The equation allowed me to create an accurate bend that allowed for the maximum bend radius while still clearing the AC.

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BarnBuiltBeaters@reddit (OP)

That's awesome! I actually designed a 3D printed tool to do that exact same thing. I determine the diameter, the CLR, and number of pieces (angle in my case). That looks really good!

How do you cut the tube? My bandsaw blade barely touched it. I ended up with a chop saw which also wasn't my favorite tool for it, seemed to squish it some. Thanks!

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SpaceTurtle917@reddit

Also, how does the number of pieces determine you angle? The reason I derived this equation is to produce any radius, at any bend angle, with any amount of pieces.

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BarnBuiltBeaters@reddit (OP)

For number of pieces, you would just need to know the angle you need to achieve. So if you are making a 90° bend and you want 6 pieces, the angle would be 15° . If you have a weird angle, it gets a bit more complicated but just simple math. I'm sure your use case is more complicated than my simplified 180 and 90 bends haha

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SpaceTurtle917@reddit

I unbolted the fence on my band saw and used a g clamp to clamp it at the right angle with a digital angle finder.

I also clamped stop blocks at the end to get repeatable length so my bends are dimensionally accurate.

How does this 3d printed tool work?

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BarnBuiltBeaters@reddit (OP)

Basically you slide it on the pipe, and mark or cut against the side of it. Honestly my pieces didn't come out repeatable and so I'm not sure how well it actually worked lol. I was a bit baffled that it didn't work or it was how I was cutting it

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Lookwhoiswinning@reddit

Looks great! One question though, are you going to make a mount for the big turbo? All that weight hanging that far out and no flex sections will destroy that tubing.

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BarnBuiltBeaters@reddit (OP)

Thanks! One step ahead of you! I made a bracket that attaches to the AC compressor mounting on the block, and ran a "bent" tube up to the turbo to support it. Curious how it hold up. End of the day it's a toy, if it sits broken cause the weld cracked i have time to fix it. Obviously don't want that to happen. I was thinking if/when that happens add a bellow into the straight section of the hot pipe

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SLEEPER455@reddit

Great work, but I can't help but think there was an easier way to do that...

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BarnBuiltBeaters@reddit (OP)

Easier, yes buy mandrel bends which cuts down on the welding alot. I like the look of these and that's why I choose it. Not everyone's style i know. Plus I really enjoy welding! Thanks though!

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jimbofranks@reddit

That looks unholy. I love it.

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BarnBuiltBeaters@reddit (OP)

Thanks! Me too!

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ModifiedAmusment@reddit

Someone should try using VGT’s in a compound set up

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BarnBuiltBeaters@reddit (OP)

I actually looked into it. I believe you need a controller for it though. Seemed a little complicated so I went the normal route for my first time!

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TomGissing@reddit

Jesus that's beautiful.

I've tried twice now to fab an exhaust from scratch and it looks like total dogshit lol. Maybe one day it'll be half as nice as this.

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BarnBuiltBeaters@reddit (OP)

Thank you! My first try didn't turn out as nice. "Luckily" it warped on me and no longer fit so I had to start over. This was my 2nd try and leaps and bounds better. Start with good material and it helps a lot!

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Aleutian_Solution@reddit

I was thinking about doing compounds on my 12v project, but I can’t really justify the cost right now. Maybe in the distant future

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BarnBuiltBeaters@reddit (OP)

I was in the same boat. A compound kit costs like 5-6g for one that isn't full of silicone boots. Hard to swallow. If you can fab, you can save yourself a ton of money. I have around 300 in flanges, 200 in pipe/pie cuts, 150 in argon. Picked up the large turbo new for 600 (since rusted), and the small turbo i bought new for 1200. All in around $2500. Obviously a lot of money but much more manageable. Hope that helps you some.

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Aleutian_Solution@reddit

Unfortunately I cannot weld, though I have a welder, it is not a skill set I currently possess

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BarnBuiltBeaters@reddit (OP)

If it's a skill you want to learn, pick up a welder. I'm 100% self taught. If I can teach myself, so can you!

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vanwhisky@reddit

gif

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shift-bricks-garage@reddit

That'll be fun. I hope to see more posts soon 🙌

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BarnBuiltBeaters@reddit (OP)

I'll keep posting updates. Unfortunately it takes me a while to finish as it's just as I have time. I have a YouTube Channel if you are interested. Same as my handle. This video should be out ina. Week or two. Need to finish painting the turbos!

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Boxman555@reddit

I got to fab one compound kit in my career and I’ll say, they’re super fun! Nice work!

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BarnBuiltBeaters@reddit (OP)

Thanks! It's my first time doing any piping and I'm happy with how it turned out. Some of the bends were a bit tight, but not terrible. This was my 2nd go at it. 1st go is in the trash lol. I don't have 5g laying around to buy a kit, so I made one!

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Boxman555@reddit

That’s what fabricating is all about! I used sanitary bends for this kind of work, you can get pretty tight radius ones so you don’t have to do all those pies. They look cool but fuck it’s a lot of welding.

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BarnBuiltBeaters@reddit (OP)

The mandrel bends would have been easier but this is the look I was going for. Not everyone's style though. Yes.... lots of welding lol. The flanges turned out amazing, the 16ga i could use a bit of work on but didn't turn out too bad either.

Once you learn to fab, you see what others are selling stuff for and realize you can make it for 1/10 of the cost!

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ZaMelonZonFire@reddit

Damn dude. Super nice work! I am just learning to tig and am trying to tackle a tight over the axle back half of an exhaust.

Keep up the great work!

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BarnBuiltBeaters@reddit (OP)

Thank you! Just keep practicing you will keep improving. Just a few years ago I wasn't great. I've been welding a bunch after work the last year or two and it's improved a lot. Best thing is to be comfortable!

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MGPS@reddit

Pardon my ignorance sir but what am I looking at? Is that a diesel? That fabrication looks awesome I love the color you picked for the coating.

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MOCKxTHExCROSS@reddit

looks to be cummins colored

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BarnBuiltBeaters@reddit (OP)

Industrial colors right? I just chose it because I liked them!

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BarnBuiltBeaters@reddit (OP)

Yes, it is a 12V Cummins. One turbo feeds into the other to multiply the boost. I will eventually need to plumb wastegates around the small turbo.

Thank you! I love the color combo too, though I stole the idea from others. I believe some industrial engines were painted roughly this same paint scheme.