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  #1  
Old 10-28-2008, 05:25 PM
dieselkid's Avatar
Dieselish
 
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Location: Baltimore, Md
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Trap Cat Bypass almost ready to roll

Thanks again Jeremy for letting me borrow your cat. Here is what I have come up with. Open for anyone.
1. Do the 4 bolt holes have be welded studs like the actual cat or can they be holes like in the pictures.
2. I didn't weld on the little side stud yet like the original cat. Is this nessesary?

Any other thoughts?






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  #2  
Old 10-28-2008, 09:22 PM
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The end of your pipe with the 4 holes is where the turbo bolts. I have a couple traps, and it`s been a while since I took it off the 85. Kind of forgot how it all looked.

the exhaust goes through the trap first, then the turbo. I think the studs are used because there isn`t a lot of room in there to maneuver some bolts.

that is a good job you did on the pipes, looks factory. then about everything I have seen you come up with looks professional

Charlie
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  #3  
Old 10-28-2008, 09:26 PM
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Trap

Cheers!

Yeh, I guess I'm wondering if I could just sell the pipe with 4 metric bolts,nuts and washers. If they will fit it will help everyone's alignment/installation of this devise.

Anyone know how important that little ear off the four bolt side of the cat is?

Thanks again charlie.

-jon
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  #4  
Old 10-28-2008, 09:38 PM
ForcedInduction
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Quote:
Originally Posted by dieselkid View Post
Anyone know how important that little ear off the four bolt side of the cat is?
I believe what you are talking about helps support the weight of the turbo.
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  #5  
Old 10-29-2008, 12:09 AM
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You may be able to use your pipe with bolts through the holes instead of studs as in the original. Looking at my installation, I estimate that it will be possible to get at the bolt heads and counter-hold them with a wrench from the bottom while tightening the nuts on top. However, if you could install the bolts ahead of time (in lieu of studs) and weld the heads in place, it would be easier for the installer.

The purpose of the little side stud is to attach two support brackets, to the head and to the block. These off-load the weight of the turbo to the head and block. I am of the opinion that they are necessary.

Jeremy
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  #6  
Old 10-29-2008, 04:29 AM
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The Ear it is. It's on the fixture that I made, just wasn't sure if it is nessessary.
-jon
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  #7  
Old 10-29-2008, 08:23 AM
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If this will fit my 1985 300CD, I would like to purchase one when they're ready.

I've been told that my poor acceleration off the line could be due to the hollowed out trap can providing an area for expansion before accelerating.

If this saves me from a complete FED conversion, I'd be very happy.
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  #8  
Old 10-29-2008, 09:41 AM
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Ear pics

Here are some other pics with the ear welded on.







I'll sell the first one here for $150 for someone to use and test since it's the prototype.

-jon
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  #9  
Old 10-29-2008, 11:06 AM
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Taking it a step further with making a whole header unit.

You can take this process a step further and make a whole Cali exhaust manifold header system. I can see having equal length runners directly to the Turbo as a PERFORMANCE BENEFIT. The Cali engines should have enough room to accomplish housing the amount of piping needed.


Just a thought.
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  #10  
Old 10-29-2008, 02:05 PM
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Just looked at my ex-CA '85 and agree that, although it would be a tight fit (she said), you could jam into the space that the trap cat occupied a nice equal-length header system. Whether it would do much good, given that the 617 head is not cross-flow, is not something I can answer, but it would be nice to see someone else do it.

Jeremy
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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970
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  #11  
Old 10-29-2008, 03:33 PM
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I would buy a header...

Jon?
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  #12  
Old 10-29-2008, 05:48 PM
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I'd need some pics and prints for the manifold. But back to the bypass.

Here are the high temp gaskets that would come with the pipe.

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  #13  
Old 10-29-2008, 06:05 PM
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What is the material?

You are aware that there are no stock gaskets on these parts.

Will there be enough clearance for them?
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Last edited by jt20; 10-29-2008 at 06:14 PM.
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  #14  
Old 10-29-2008, 06:33 PM
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The turbo has a rectangular gasket like the one shown between the turbine and the manifold on FED cars
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  #15  
Old 10-29-2008, 06:44 PM
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oops, forgot about that.. it is the thin metal plate with a crush cuircumference, right?

jon, what are the thicknesses of these gaskets?

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