LHT V8 Turbo manifolds

[MrLHT]

We had the opportunity to build tubular manifold for a Form lightening with merge collectors and merge into one hugh single turbo the customer supplied.
The Motor is a 5.4L built SOHC with 1000 whp in mind, The turbo is a Precsion GT4788 with a T6 in and 5" out to the down pipe.
The turbo was so large finding a place to fit it in the engine bay and still have room for a downpipe and charge pipes took the help of the engine lift.

http://i89.photobucket.com/albums/k231/lhtperformance/DSC01649.jpg

This give you an idea of turbo size with my Sony K800 sitting in the inlet.
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01677.jpg

Both headers, one fully welded the other tacked.
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01641.jpg
Anyone that has built header before knows the time involved, the lower of the two is the drivers side which has the steering colum pass throw it,

http://i89.photobucket.com/albums/k231/lhtperformance/DSC01668.jpg

[MrLHT]

This the the merge, the 2 pipes meet and a TIAL 60mm waste gate ( Supplied by customer) hopefuuly controls boost.
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01652.jpg


http://i89.photobucket.com/albums/k231/lhtperformance/DSC01655.jpg
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01666.jpg

All the welding was back purged with a route weld then filler weld for strength, For the this you need a second bottle with regulator to force the air from the insed of the pipe.

http://i89.photobucket.com/albums/k231/lhtperformance/DSC01657.jpg

Inside of the pipe
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01659.jpg

[MrLHT]

Here's some shots of the custom intercooler we built, We used a Precision core capable of 1200 HP and built our own end tanks.

http://i89.photobucket.com/albums/k231/lhtperformance/DSC01593.jpg

Welded end tanks.
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01597.jpg

No leaks here..
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01598.jpg

[Liquid]

dats jus crazy!

[sleepinsol]

thats gonna be one bad pickup!!!

[jlude90]

you guys do such fantastic work, i can't wait to see this thing done

[Liquid]

another great one off

[boca]

lol^

[MrLHT]

Somehow I can't see there been a great demand for this kind of set up, Maybe we should spend hours building fixtures just in case.

[F&H Performance]

Thats the best welding I've seen in well i think ever.

[MiDiablo]

You should post a link to this in the Ford Tech Forum :dunno:

I bet you'd get some info from the Ford Lightning Owners in there... Also, look into posting over at some of the L Forums, like "NLOC" for instance.

Fab work looks insanely awesome!

-Jo$h

[Alpha]

Great work John! What is new though :lol: That turbo will make 1000whp. We made 1034whp through an auto with more left in it. It's hard to tell from the pictures but I assume there wasnt enough room to prioritize the wastegate more? I'm sure it wont be an issue with the boost he will be running though

[MrLHT]

Thanks guys. Alpha, There wasn't much room for the turbo let alone anytning. I think it will be fine as he will be running high boost most of the time.

[smokeshow]

The intercooler welds look good!

On the tube/pipe, are you doing open root? Or bevel/feathered edge?

309?

[freakyfast95GTS]

Here's some shots of the custom intercooler we built, We used a Precision core capable of 1200 HP and built our own end tanks.

http://i89.photobucket.com/albums/k231/lhtperformance/DSC01593.jpg

Welded end tanks.
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01597.jpg

No leaks here..
http://i89.photobucket.com/albums/k231/lhtperformance/DSC01598.jpg


such nice welds around the seams but whats with the top pic welds where the tanks meet the core? did you grind the blobs down? or is it just a pic-figment?

[civicSi07]

^ thats where he tack welded it to hold the tanks in place

[MrLHT]

The "Blobs" are tacks to hold it in place. Aluminum pulls and mishapes as it's welded or heated. Once we come up a tack, we grind it off than continue the weld.