At the Peterborough Show, managed to buy a 300 TDI disco exhaust downpipe for a fiver. As this has the same flange that fits to the turbo, it can be used to fabricate a custom downpipe.
Downpipe as brought:
First job was to cut off the end of the downpipe, at the turbo end. Then cut out the 90 degree bend in the pipe, and weld this onto the end of the flange.
The end of the curve is then trimmed to allow for a tighter bend from the turbo. This is necessary due to the the lack of space between the turbo and the bulkhead.
This is what it will look like once welded together:
The flange is then fitted to the turbo, and the downpipe held in position, whilst I put a couple of tack welds to hold the two pieces in place.
The downpipe is then placed in a vice, and welded all round:
Once welding is completed, the downpipe is ready to fit back on the turbo.
Once I've brought a defender exhaust, I'll convert the defender front pipe to fit onto this pipe, and weld the two pieces together.
