Herr-Kuhn

I sent the new twin turbo manifolds, turbine housings and downpipes out to New York for application of the Swain TBC-EX. This is a true ceramic coating, not a high temp paint like you get with jet hot or others. Originally I had the Callaway manifolds done here in town with a "2000 F coating". It did not last. The Swain coating is pearl white in color and is a three step process. The ceramic is sprayed out of a guy as molten material, the 2nd layer is 20,000 F when it leaves the tip of the gun. Once it hits the part it immediately cools and adheres to the surface.

I was skeptical of the coating because of the high cost. Last night I assembled all the new manifolds and the like to the stand motor. I had to open up the holes in the downpipes a bit because the coating adds about 0.020" of build. I took a bastard file and spent a few minutes...no luck. I had to get my dremel out with a hardened steel bit to get through the coating. I could not believe how strong the coating and the bond was.

The new setup looks wicked on the stand motor...makes for a really nice picture...one step beyond the Goldmember, though it is the same design. The contrast between the exhaust and the rest of the motor really makes it stand out.

I'll be firing the car sometime next week after I make a few more parts. The TBC-EX is supposed to be the best coating available today. I used the coating to keep underhood temps down, to help hold in heat to drive the turbines and to preserve the manifolds from high temp oxidation. Three birds with one stone... I opted for mild steel with the coating instead of stainless steel.

I'll post some photos soon.

Shane

Pics John Pics!!!!

DR

Hi John,

Yes, we need PICS!!

BTW, that coating sounds very familiar to "GIL Coating" as used by GIL Marine on their Jacketed Headers for Boat Racing Engines. I had some on my offshore racer many years ago and it was just as tough as you describe, the surface felt more like "porcelain ceramic" and was amazing stuff..

Oh yeah, it was also very expensive even back then. I remember the headers with this coating was over $3500 per engine and that was back in 1990 !!!

Herr-Kuhn

I have to wait for my memebrship to clear before I can put the pictures up. Wow, over 3K...that is insane. I got all the the mentioned parts done for $600.00 even. That is two manifolds, one wastegate pipe, two turbine housings and two downpipes. This would have been about equal to fabbing the manifolds from stainless without coatings. Stainless warps big time on manifolds of this nature after you take them off the jigs. Then there is the high expansion rate and you would still not have the full insulating properties you get with the coating.

I've toyed with header designs for the turbo 928, but there are big disadvantages...too much surface area makes more heat, long tubes expand a lot and will crack, plus just fitting it in there. The turbo can work with even the crudest of exhaust systems. I talked with a guy that built a Bonneville 383 cube engine with twin turbos. For space reasons, the manifolds were made from box channel bolted straight to the engine...no flanges, no runners, just a box channel bolted to the heads with two remote wastegates and turbos. It made 800 HP. It was claimed to look like a box toaster bolted to each head.

As soon as my membership comes through I will put the pictures up. This time with some ID tags so we all know where it came from. That is the problem with the internet...once you show it it is free for the world to copy!!!! I fear that there will be a Chinese Goldmember sometime soon! These pipes look so good I almost don't want to run them...I said almost.

DR

hi John,

Just for clarity sake, that was for the "wet" header system with the coating. I just checked online and the price has come down since then (they were cutting edge at that time).. They sell now for "only" $2600 a set! But hey, I picked up 3-5mph on the top speed of my boat and back in those days that was well worth it... and people think 928 parts are expensive...Geez!!

Herr-Kuhn

Phew....wish I could get that for my manifolds system...I'd go get them cast from iron if that were the case.

DR

John,

Ironcially I sold a 6 year old set of those for $1900 in the mid 90s, AND with that coating they still looked exactly (inside and out) as they did new.

BTW, sorry for getting off topic, your post just brought back so old memories.

Merry Christmas !!

BC

Swain is great. I had my pistons done there. I should have had my headers done there, but was concerned about shipping. I've been having some issues with shipping, even with insurance.

Herr-Kuhn

Your issues are probably with UPS. My local driver did not qualify for the "sharpest tool in the shed" award this year either. UPS actually desroyed the crate I shipped the Goldmember's block in. It had to have been dropped off the back of a truck. Luckily there was no block damage. And to think those drivers make $70,000+ per year. Why did I go through 9 years of college?

Swain makes a piston skirt coating that can be used on Alusil...though there is no guarantee of longevity. This White Lightning header and exhaust coating is so far ahead of any "spray and bake" coating. All the others are just high temp paint by comparison. Yes, it cost 2X, but I know it won't flake off after a year or a hard boosted run. I considered the skirt coating to avoid having to Nikasil the new block...but since the S4 already has 170,000 on the clock I'd bet the bores are out of round already. I'll probably just stick with what I know.

Jim_H

I don't know, it's only supposed to take 4, Homer. Merry Christmas.

Herr-Kuhn

I failed to mention that is for a BSME and MBA...and I'm glad I did it! Let's hope I have enough smarts to be able to build and market something interesting...

Jim_H

Build it and they will come...

Jim_H

Are you talking about the pics you sent me? I think it's ok for me to post them.

mspiegle

Did he send you the cute girl too?

Jim_H

Oops