Sched 40 is massive thick… sched 20 is the max you realy want to go… these are cast pc’s and as such they retain heat ~ 2x more eff. then the OEM cast iron one. Wrap it up!! and don’t weld a non stainless O2 bung to it it will split off, stainless has a MUCH higher heat expansion rate then mild steel. This goes for the flange too… ( unless you can find some High Ni. HRS )
Straight schedule 40 NSP tubing is used between els. These parts have a very thick wall thickness so the header will probably weigh as much as a heavy cast iron manifold. This thickness is necessary with non-stainless tubing for longevity at the high temperatures encountered. Standard mild steel header tubing will quickly self destruct if used for a turbo header
ANY welding shop that does high pressure or food industry welding will use these. metals supermarket would probably have the sched 40 in stock.
Sched 40 on an unsupported turbo is to be expected, not very good design practices but fairly typical. the exducer elbow/DP/turbo elbow, whatever term you guys decided to use today, can be MUCH lighter as it’s ( not suppose to anyway ), not supporting any weight .
I’m also considering 16-gauge steel since that’s what my manifold is
made of. Or should I at least consider the 90-deg Sch40 elbow as the
flanged end on my downpipe?
And I plan to fab a makeshift turbo support brace (to put as load as
possible on the manifold or downpipe).
I also have a Megan flex-piped exhaust downpipe FYI.
I built my downpipe and exhaust with 18 gauge mild mandrel bends. You can order them through anyone that deals with Keystone, i.e. speed shops, partsource.
~$35-$40 for a 3" 180 degree mandrel bend (You can cut it to get two 90 degree elbows, or four 45 degree elbows).