Hello, V10 treg is my pet-project and Im working on some engine mods. I came up with necessity for better flowing and much more robust exhaust manifolds. Extensive logging on stock engine with "all-in"-style tune showed engine choked, and having replaced stock manifolds few times due to cracks Im trying to opt for cast manifolds.
I created a model checked it fits by 3d scaning whole car and engine and applying that new exhaust manifold model there.
Im from EU and my goal was to keep things as much stock-ish as possible i.e. EGR in place and no monster headers under the hood with dual 2260 instead of air filters (we have video fixation on technical inspection sent to common state storage now...).
Stock exhaust manifolds are done as welded pressed pieces with tiny pipe inside. Inside common collector pipe is of some ellipse shape but its area has been calculated to be same as a circle of 32mm dia. I.e. 2.5L 5 cyl. diesel is "breathing" through 32mm pipe (before turbo). I know they wanted to make it spool faster especially given our stock turbocharger coming directly from 1995 renault with 1 to 1 internals and different casing, company might have achieved what they wanted though everyone who goes gtb2260 there on huge manifolds gets faster spool response than stock...
Personally Im gonna experiment with other TC that will fit into stock place, maybe constructing somne hybrid solution which remains only stock central housing... So I needed better flowing and more robust manifold which can be mounted on any side of engine.
I have found a company in China that (among other companies I asked across Europe and China) offered some acceptable pricing for making hundred of them.
Now I'm looking for people who would like to participate in collective order of those castings.
You will receive just 2 universal (left/right) manifolds with machined surfaces and v-band flanges i.e. ready to be installed but without any extra stuff like clapms gaskets bolts etc...
I'm sure I can handle overseas shipping from EU by the company of your choice and at your expense of course.
Currently I'm looking to offer a set of manifolds (2: 1 left + 1 right) here at my shop for 450$.
On the next images you can see insides of stock exhaust manifold and my proposed model with 2 different v-band flanges 1.5" and 1.75" please write what size you prefere as each manifold must have same v-bands to be universal so hundred of same units can be ordered, based on most preferences final order will have only one size so everyone will get same sizes.
Chart is showing stock engine performance with "all-in" tune in regard to compressor pressure ratio and mass air flow. Each graph is a trend to get rid of RPM and instead focus on difference between 100% volumetric efficiency mass flow and real one. The point is stock engine loses VE very fast and from about 3000rpm has ~70% VE i.e. in stock form you pay for 4.9L but only using ~3.5L of that, no brainer 3.0 v6 tdi can be on par or outperform our 4.9/5.0 V10... Based on dyno charts and logs from other 2 valves brothers like 1.9tdi and some 2.0 tdi and flow metrics on v10 cylinder heads with stock cams I derived that huge 30% VE loss at middle rpm is not caused neither by 2 valves nor by cam profile, having large unused air mass available right before intake and been not able to open VGTs more without losing boost means exhaust gass flow is choked somewhere before turbine. 52mm Compressor should be maxed around 25lb/min according to old garrett maps for 52mm compressor, but in our engine it is stalled at 23lb/min around 3300rpm and just keeps that.
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I created a model checked it fits by 3d scaning whole car and engine and applying that new exhaust manifold model there.
Im from EU and my goal was to keep things as much stock-ish as possible i.e. EGR in place and no monster headers under the hood with dual 2260 instead of air filters (we have video fixation on technical inspection sent to common state storage now...).
Stock exhaust manifolds are done as welded pressed pieces with tiny pipe inside. Inside common collector pipe is of some ellipse shape but its area has been calculated to be same as a circle of 32mm dia. I.e. 2.5L 5 cyl. diesel is "breathing" through 32mm pipe (before turbo). I know they wanted to make it spool faster especially given our stock turbocharger coming directly from 1995 renault with 1 to 1 internals and different casing, company might have achieved what they wanted though everyone who goes gtb2260 there on huge manifolds gets faster spool response than stock...
Personally Im gonna experiment with other TC that will fit into stock place, maybe constructing somne hybrid solution which remains only stock central housing... So I needed better flowing and more robust manifold which can be mounted on any side of engine.
I have found a company in China that (among other companies I asked across Europe and China) offered some acceptable pricing for making hundred of them.
Now I'm looking for people who would like to participate in collective order of those castings.
You will receive just 2 universal (left/right) manifolds with machined surfaces and v-band flanges i.e. ready to be installed but without any extra stuff like clapms gaskets bolts etc...
I'm sure I can handle overseas shipping from EU by the company of your choice and at your expense of course.
Currently I'm looking to offer a set of manifolds (2: 1 left + 1 right) here at my shop for 450$.
On the next images you can see insides of stock exhaust manifold and my proposed model with 2 different v-band flanges 1.5" and 1.75" please write what size you prefere as each manifold must have same v-bands to be universal so hundred of same units can be ordered, based on most preferences final order will have only one size so everyone will get same sizes.
Chart is showing stock engine performance with "all-in" tune in regard to compressor pressure ratio and mass air flow. Each graph is a trend to get rid of RPM and instead focus on difference between 100% volumetric efficiency mass flow and real one. The point is stock engine loses VE very fast and from about 3000rpm has ~70% VE i.e. in stock form you pay for 4.9L but only using ~3.5L of that, no brainer 3.0 v6 tdi can be on par or outperform our 4.9/5.0 V10... Based on dyno charts and logs from other 2 valves brothers like 1.9tdi and some 2.0 tdi and flow metrics on v10 cylinder heads with stock cams I derived that huge 30% VE loss at middle rpm is not caused neither by 2 valves nor by cam profile, having large unused air mass available right before intake and been not able to open VGTs more without losing boost means exhaust gass flow is choked somewhere before turbine. 52mm Compressor should be maxed around 25lb/min according to old garrett maps for 52mm compressor, but in our engine it is stalled at 23lb/min around 3300rpm and just keeps that.
Im going to handle all costs for foundry, machine shop (flanges) and packaging for bulk order as I doubt people will send money to some noname without photos of all manifolds in ready to ship condition, so Im looking for more people who at least potentially will buy it as I don't want to unload some money and be left with tons of stainless steel in my place 
