EWG w/ stock manifold

[speed3sailor]

Alot of you probably have seen @h.h.sk1nny; s thread about running the BNR S3 EWG with the stock exhaust manifold. He is now going back to pursue a K04 11sec 1/4 mile so i ended up with his BNR. The internal wastegate is welded closed so i started working on making my manifold EWG also. Let me start by saying that the cast iron is a pain in the butt to cut through. It doesnt really help that i dont have the right tools to cut it with though. He said he used a hole saw to cut it but that didnt work very well for me. I ended up using a step drill bit and some time with a dremel. I then used a piece of 38mm forged iron tube that i found at a local harware store. Only about 1 or 1.5 in of it was used. I had to dremel the bottom to match the exhaust manifold since it is curved. Then i had the Vband flange that came with my EMUSA EWG welded onto the pipe and the pipe welded onto the manifold. The welds look pretty good. I am located in Italy so i had to get some guy that spoke very little english to weld it up for me and he used a stick welder. we will see how long it lasts.

I ended up using a cutting wheel to go back and cut off all of the stock heat shield mounting points because the welder couldnt get to one spot very well and i wanted to wrap the whole thing in heat wrap. After the cutting wheel, i went back with a grinder and after the grinder i used a dremel again to make it all smooth.

This is the first thing i have ever heat wrapped and i think it went pretty good. i was going to cut out the metal between the first 2 runners but ended up saying screw it and just wrapped them together. I was going to wrap around the entire thing but realized it would be good to be able to make sure the welds are not cracking. I ended up painting it also.

I have to get the angle of the dump tube changed to clear the downpipe but other than that, it is done.

[h.h.sk1nny]

Looking good buddy!!! This setup is freaking sweet!!! EWG is gonna put a massive grin on your face lol. Let me know if you need any help with anything. Running lines for the 3 port is super easy too. Have fun with it

[speed3sailor]

Originally Posted by h.h.sk1nny Looking good buddy!!! This setup is freaking sweet!!! EWG is gonna put a massive grin on your face lol. Let me know if you need any help with anything. Running lines for the 3 port is super easy too. Have fun with it

Thanks. I can't wait to get it running again. Thanks for all the help.

[speed3sailor]

If anyone is interested in what parts were used or have any questions on how to do this, let me know.

[CWP_MS3]

Originally Posted by speed3sailor If anyone is interested in what parts were used or have any questions on how to do this, let me know.

Post a video yo!

[speed3sailor]

Originally Posted by CWP_MS3 Post a video yo!

It's still not up yet. I'm starting to go nuts. It's been 2 months. I'm waiting on my FMIC still. It should be up by next weekend. I'll post videos soon.


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[truredms3]

i might need your knowledge with this im planning on doin this very soon.

[truredms3]

Have you been running this yet ? How's it holding up if you r

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[Da6d]

I love external wastegates. I'm curious to hear a DISI ewg. (In person) I too will be ewg on the 6 just waiting. My expectations are kind of in the middle, the last ewg setup I had was:

R33 Skyline GTS25T Open wastegate/screamer pipe 38mm tial - YouTube

R33 Skyline GTS25T Open wastegate/screamer pipe 38mm tial - YouTube

I'm hoping the DISI sounds even half as good. Post up that video!

[speed3sailor]

Originally Posted by Da6d I love external wastegates. I'm curious to hear a DISI ewg. (In person) I too will be ewg on the 6 just waiting. My expectations are kind of in the middle, the last ewg setup I had was: R33 Skyline GTS25T Open wastegate/screamer pipe 38mm tial - YouTube I'm hoping the DISI sounds even half as good. Post up that video!

That's about how it sounded on spring pressure. Now that it's cranked up, it sounds different


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[Chimmike]

I wouldn't count on those welds lasting long. Welding on cast iron is almost a guarantee of cracks.

[speed3sailor]

Originally Posted by gingermike I wouldn't count on those welds lasting long. Welding on cast iron is almost a guarantee of cracks.

we will see. H.H.sk1nny has been running his for like 6 months. The welds on mine look much better than his(not talking trash) and were done by a professional who welds cast iron frequently. This is not a permanent mod and I suspect it will hold up longer than I plan on using it.

If it does crack. I will post that on here as well. I wont try to hide it.

[h.h.sk1nny]

^True story. I have been running a good solid 6months, issue free. I actually just plopped a stock k04 back in and got a thorough inspection on my bird turd welds. Still looking ugly, but no cracks at all. A lot of old school guys think it is impossible to weld cast iron, but it has come a long way. They have welding rod that is meant for cast iron. Few tricks like heating up the piece being welded and cooling it off in the sand will help how long the weld lasts too; I did neither.

[speed3sailor]

so, ive been running this EWG setup for about a month now. It is working great now that I got a new Tial wastegate. The EMUSA wastegate didn't work out for me. Here is what my setup looks like now.

[GOT 2RBO]

videos and more info!!

[speed3sailor]

Originally Posted by GOT 2RBO videos and more info!!

ill post videos soon. this thing sounds crazy. its making some good power though.

here is a comparison of the K04 vs BNR S3. im still in the process of tuning. more power is to be had.

[speed3sailor]

Mazdaspeed3 30-110 - YouTube

Mazdaspeed3 30-110 - YouTube

[Status Update]

I love the sound of that ewg flutter!

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[speed3sailor]

Originally Posted by Status Update I love the sound of that ewg flutter! Sent from my DROID RAZR using Tapatalk 2

I love it too. Especially in the first couple gears when I'm spinning and the dump tube is shooting out all kinda of crazy flames and popping and stuff. I need to extend the tube a little bit so it's flush with the bottom of the car though.



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[ciezczak1]

Originally Posted by speed3sailor I love it too. Especially in the first couple gears when I'm spinning and the dump tube is shooting out all kinda of crazy flames and popping and stuff. I need to extend the tube a little bit so it's flush with the bottom of the car though. Sent from my iPhone using Tapatalk

How are the welds holding up on the ewg?

sent from the s5

[speed3sailor]

Still going strong. No cracks or issues of any kind.


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[LatinKraze]

I'm planning on doing this. Thanks for the vids. Sounds wicked

[Gr8Speed]

Bumpin dat old thread. I'll be doing this soon. Tial MVR 38mm on a BNR S2. What flange did you use?

[speed3sailor]

Originally Posted by Gr8Speed Bumpin dat old thread. I'll be doing this soon. Tial MVR 38mm on a BNR S2. What flange did you use?

one that comes with the Tial plus a small amount of tubing that was welded to the manifold to raise the flange a half inch or so because its hard to put a flat flange on a round runner.

in the original post i said that i used the vband flange that came with the Emusa wastegate but that wastegate was a POS and when i got the Tial, i swapped out the flanges just to make sure everything sealed good.

[speed3freak89]

@speed3sailor i am interezted in doing this looked over your setup several times. What did u spend in the build for the materials.?I know its been a while since post did anything go wrong with it?

[speed3sailor]

Originally Posted by speed3freak89 @speed3sailor i am interezted in doing this looked over your setup several times. What did u spend in the build for the materials.?I know its been a while since post did anything go wrong with it?

the only thing I had issues with was with firewall clearance. I would get whoever is doing the welding for you to just spot weld it and then check fitment. I still don't have a ton of clearance but have never had issues with it touching the wall. its been a year and a half and going strong.

[MSP6]

Old ass post bump FTL but meh....

you have to add a ; to the end of your mention.
@speed3sailor;

[speed3freak89]

@MSP6; I know its a old thread but i am interested in his EWG build on stock manifold. Been something i ben wanting to do since i uograded my turbo.

[MSP6]

@Vansquish; I had to to tag you...

Also @speed3freak89; No biggie, which is why I said "meh". I'm forced to work 6am-6pm today and I'm bored as shit so I was hoping OP had updated this with something to entertain me for a few minutes.

[Vansquish]

LMAO..."interezted"

[SuckSqueezBangBlow]

Good work! Nice to see someone trying this with the stock mani. Hell if it fails a used one shouldn't be hard to find. Fingers crossed for you!

[speed3freak89]

@ SuckSqueezeBangBlow; another member has done it as you can see by pics. I am planing on buying used stock manifold off ebay. Found a couple for $90. Im gonna do my EWG project on that incase something happens i still have my stock manifold. As soon as i get the used manifold and a EWG i will get on with the build. I will post pics of build.

[speed3freak89]

@speed3sailor; thanks for that info. I will be doing all the work myself. I will definately keep that in mind.

[speed3freak89]

Finally got Tial Wastegate and welded it in manifold. Looking for a better way to keep the old IWG valve on exhaust housing closed. I got it closed but i am wondering what orhers did . I dont want to weld it closed incase i need it in future if anything were to happen to the EWG.

[g00s3y]

Doesn't Cobb make an adjustable IWG bracket so that you can keep it closed all the time?

[joeyspeed3]

Yep they do lots of people use it go check them out

[TRBLSM]

You can just take weld the flapper closes and disconnect the actuator arm. Only need to grind the tack welds to revert back. Or go the cobb bracket


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[LatinKraze]

Holy shit! Is that how you're leaving the dump tube?

[Etipp98]

So many things wrong in that picture

[jdmage_mx5]

Originally Posted by Etipp98 So many things wrong in that picture

I thought the exact same thing when I saw it.

Dump tube in terrible spot
Oil catch is in a terrible spot
No clamp on MAF housing to intake coupler
Air filter is so dirty it's probably performing worse than stock

I'm sure there are a few other things I'm failing to mention. I will solute you though on the EWG on stock manifold; just extend the dump tube down to keep the fireballs out from under the hood.