Fitting the weapon R to a VX

Karlosfandango

OK, so how the fuck do you get the new manifold on then? There is no way on this earth that it will fit through any of the existing gaps unless I'm missing something? Is it clam off time?

vocky

you have to cut a hole in the clam :shock:

like this

I can make you one of these for about £50 dunno..

Karlosfandango

I've cut the hole but there is no way it will pass through it, it looks to be the exact same size as yours, am i missing something?

vocky

have you also cut the clam heatshield, the one the clam sits on notsure.gif

I have since cut the corners to a 45 degree angle (see pic above)

Karlosfandango

Are you sure that the manifold can be removed through the hole once the clam is fitted? If so then it must be a case that the hole needs to be made bigger.

vocky

I think it was rabidh who fitted his without removing the clam, I've not tried but it looks like it would fit through the hole

Karlosfandango

I was being gay, so have hacked a load more out. Which gasket do you use with the weaponR? The one that comes with it looks like it blocks the little channel that is at one end of the manifold.

vocky

I would flatten both the manifold flanges first with a belt sander (where it joins the head and where it joins the downpipe), then use the vauxhall exhaust manifold gasket and buy some universal 2" gaskets for the downpipe connection

Karlosfandango

Good info, the vauxhall gasket has sections that run across the openings in the weapon R manifold should I just cut these off?

I've made a basic jig up to help father in law make the new system..

Is there any particular part of the exhaust system that you have to watch or be overly careful with? I'm thinking that as long as the manifold position, hanger point and end of the U are in the correct position the rest should work out as along as they are kept within in a fairly close proximity to the original.

vocky

you need to reinforce the manifold part of the jig, you don't want it to flex

otherwise it should be fine, the only problem I had was making sure the downpipe cleared the engine tray

also worth noting the U bend should try and stay clear of the tyre, so perhaps a piece of wood to keep it within the spec, the flange connection should perhaps move a little closer to the cat

rabidh

When I used the weapon-r gasket I had leaks all over the place. The standard GM one seems way better - I didn't have to cut any bits off at all. What I did do though was fill the channel in the WeaponR gasket with weld. It's just for the EGR, which I figured I'd never use anyway.

The jig looks great. Only things I had trouble with on mine were:

Positioning of the cat so it didn't touch the undertray - I used a big one and I had to fit it at some odd angle
Getting the bends on the 2:1 to end high enough that the Y piece didn't hit the undertray.

Just looking at the jig though... if you're using 2.5" pipe, then maybe the supports you've made will push the pipe a little bit higher than it needed to be? Isn't the standard pipe only 2 inches?

alanoo

These exhausts are driving me crazy; but now that I paid (a lot) for this crappy 4/2/1 i'll fight until they make me something worth it

Karlosfandango

Haven't got too much done apart from making the boot hole cover. I'm currently wondering what the best thing to do is regarding heat shielding the boot. The cover I've made up is 3mm aluminium sheet and should sit about 20mm+ away from the manifold. Would just wrapping the manifold be sufficient or should I find something to line the inside of the cover aswell/instead?

vocky

I have removed the lagging on my weaponR, instead I have used fibreglass/silver covered matting on the bulkhead / heatshield

Karlosfandango

What torque are the exhaust manifold bolts done up to? Does anyone have a link to the online workshop manual?

winstar

Karlosfandango said:
What torque are the exhaust manifold bolts done up to? Does anyone have a link to the online workshop manual?

All the torque's you'll ever need

http://www.speedsterclub.nl/bibliotheek/technische%20documentatie/tis/Standard%20Information/Engine%20and%20Engine%20Aggregates/00031676-Torque%20Guidelines%20(Z22SE).pdf

Karlosfandango

Super!!

Is it really only 12nm?? Hardly seems tight enough? Will the heat/expansion in the parts cause this to tighten up?

vocky

I tighten them to about 20Nm rather than 12 Nm, which seems a bit loose

cthomas443

Fitted my weapon-r this weekend.

When i removed the standard manifold the two nuts at the passenger side of the head took hardly any effort to undo and 5 studs came out with the nuts around the branches.

I had to do i think 4 nuts up with a ring spanner guestimateing the torques when fitting the weapon-r.

Is everyone running 02 simulator sensors as im running both standard lambada's with no eml yet.

OAKMERE

cthomas443 said:
Fitted my weapon-r this weekend.

When i removed the standard manifold the two nuts at the passenger side of the head took hardly any effort to undo and 5 studs came out with the nuts around the branches.

I had to do i think 4 nuts up with a ring spanner guestimateing the torques when fitting the weapon-r.

Is everyone running 02 simulator sensors as im running both standard lambada's with no eml yet.

Well done Any pics?

Do you have a list of parts used?

Cheers Oakmere

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