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-   -   F575 sport exhaust manifolds (https://www.ferrarilife.com/forums/modern-v12s-456-550/39098-f575-sport-exhaust-manifolds.html)

550_Maranello 12-04-2014 09:20 AM

F575 sport exhaust manifolds
 
6 Attachment(s)
Hello at all guys,
i think it is the time that I explain my project, that is arrived almost at the end, i'm working since august, I work on this project during my less free time ....
Who of you have seen the original precats of 575 know how they are bad designed ....
It was a long time that i would to do a manage the sound of maranello's in order to have a sound more acute, more clear but in same time to not have problem it with the check engine lamp and with the pollution.
I have designed for this engine family an exhaust system like the 599 GTO and the last series of V12 F , in detail one manifold 6-1 plus one big 200 cps metallic catalyzer of high quality.
I have designed also the version without catalyzer and without secondary air pipes.
I have developed a 3d model of the engine and part of chassis by myself in order to do a preliminary study before exhaust removal from the car, i have replicated exactly the secondary air pipes and flanges in order to fit to the original system of the car.
V clamp and gasket are made by my design, i did to do a discrete number of pieces, the gaskets was from a manufacturer for Ferrari and other sport car ...
On the car are not necessary any cutting, or other modification, in every time is possible to be back at the original.
The original exhaust of 575 (2 precats + 1 big cat) = 17.2 Kg
my exhaust (4.4 manifold + 3.6 cat + 1.5 pipe) = 9.8 Kg. this for each side of the V12.Tomorrow i pick up the two manifolds from the cleaning shop, and within the end of the year i will finish all.
As soon as possible will post the end of project and a video about the new sound, and obviously the driving impressions ...
I have designed and built also the jigs in order to can built every piece without the car, it was a big work and difficult to find a space for the two big cat ... ...
My Ferrari dealer think is a good improvement of this engine.
From the the new year i will be ready to produce this manifolds, if someone will be interested.
I have sold one manifold without cat at one my friend that have a 550 and him go on track, i will deliver between some weeks, when he seen ... was enthusiast!
I need to thank cribbj for the help about the chassis dimensions ....
I would have thousand things to write .... If you have questions i'm here.

tazandjan 12-04-2014 10:46 AM

Fabio- Very nice. The only other set of manifolds on the market have to be bought with a full exhaust system and are very expensive (~$15k).

550_Maranello 12-04-2014 12:32 PM

Quote:

Originally Posted by tazandjan (Post 514722)
Fabio- Very nice. The only other set of manifolds on the market have to be bought with a full exhaust system and are very expensive (~$15k).

Terry,
the only set of manifold that i know is made by italian supersprint but they are 3-1 + 3-1 and not have all air secondary pipes ....
My pipes have thickness of 1.2 mm.
My system will cost about half ....
If the results will be nice, i will do also a titanium version.

tazandjan 12-04-2014 12:53 PM

Fabio- Affirmative, that is the one I was thinking about. Yours looks far superior. Will you have heat shields or will the OEM shields work?

Titanium will be interesting, but stainless may be superior in that application.

550_Maranello 12-04-2014 01:26 PM

Quote:

Originally Posted by tazandjan (Post 514786)
Fabio- Affirmative, that is the one I was thinking about. Yours looks far superior. Will you have heat shields or will the OEM shields work?

Titanium will be interesting, but stainless may be superior in that application.


Terry,
before start my project i seen their manifolds but for me the price is too high, i don't like the design and the quality of construction ....
The original shields remain in place, 575 have a good shields over the pre-cats, i have designed one shield to install under the first two pipes and over the engine support in order to repair the rubber support.
The catalyzer will be covered by ceramic wool (2 mm thk) and all covered by embossed alluminium, i have buy this material in Torino from a company that working also for F ....
I did a bunch of drawings for this exhaust and for the machining i went from a specialized company with CAM machines ...
Catalyzer have area over 20% and volume 45% of the sum
of the two pre-cats originals, that are 300 cps, my catalyzer supplier told me that i not will have problem with lamba or check engine lamp, that is one of my most objective.

Yes Titanium will be interesting, but also expensive,i think that stainless steelis a good choice.
The six cones that are on the union point are made by my self with plastic deformation of round pipe ..... i have designed a proper equipment....
also for cut the curves i have designed a proper equipment....

KonaDog06 12-04-2014 02:52 PM

Fabio, Most Impressive!
Enjoyed reading of your work and will watch with interest.
Thank you,
Bill
FL

550_Maranello 12-04-2014 03:19 PM

2 Attachment(s)
Quote:

Originally Posted by KonaDog06 (Post 514842)
Fabio, Most Impressive!
Enjoyed reading of your work and will watch with interest.
Thank you,
Bill
FL


Bill,
thanks.
follow the race version without secondary air pipe and without cat.
On second picture the jig for welding of air pipe and flange spacers.
The single flanges are completely machined with hole from oval (head side), to round (pipe side).

212Export 12-04-2014 09:08 PM

Absolutely gorgeous looks, Fabio ! Congratulations for bringing a long project to a great end ! I'm sure that many owners will have a profound look at your product. Can't wait to hear and see it in real (Video) !

550_Maranello 12-05-2014 01:47 AM

5 Attachment(s)
Quote:

Originally Posted by 212Export (Post 514930)
Absolutely gorgeous looks, Fabio ! Congratulations for bringing a long project to a great end ! I'm sure that many owners will have a profound look at your product. Can't wait to hear and see it in real (Video) !

Hi 212, thanks ... I have also some work to finish, but as soon as possible i will post a video ....

This morning i picked up from the galvanic treatment the two manifolds, i did
pickling ( to remove welding residues) plus micro peening and final passivation for corrosion inhibition, the company that did those treatments work also for F1 parts.

The results are on following pictures ....


I like them!

550_Maranello 12-05-2014 02:36 AM

3 Attachment(s)
This is a jig for curves cutting that i have invented by myself, i had buy mandrel curves type and i lock the curve under cutting by means of expansion elastic mandrel.
On the rotating part i have done angular reference notches, the elastic mandrel is positioned by center pins doing the center of the curve perfectly on the pivoting axis.

550_Maranello 12-05-2014 02:41 AM

4 Attachment(s)
Detail of head flanges ....
And difference between old and new cat.

212Export 12-05-2014 05:47 AM

Wow, great work Fabio, those manifolds look crisp....to say the least. Now I only Need to get a Maranello ;-)

550_Maranello 12-05-2014 06:02 AM

Quote:

Originally Posted by 212Export (Post 515114)
Wow, great work Fabio, those manifolds look crisp....to say the least. Now I only Need to get a Maranello ;-)

HAHAHA 212, you was near to close some month ago for a maranello .... but your
Scud is great! like your other two F ....

Wait till you hear the sound .... ahahah:thumbsup:

p.s. : next sunday we will go to "La Cesarina" in Bologna ... you remember something... ?

tifosi_ 12-05-2014 06:43 AM

Those look awesome Fabrio! Maybe you should be working for Ferrari?
Clyde

550_Maranello 12-05-2014 06:56 AM

Quote:

Originally Posted by tifosi_ (Post 515162)
Those look awesome Fabrio! Maybe you should be working for Ferrari?
Clyde

Hi Clyde,
hahaha ... now is too late .... They have not wanted me 14 years ago for the thesis .....
Thanks you are kindly ....
Tomorrow I will work on catalyzer ....
I have my 575 on my workshop since first october and i asked to the mechanic of my Official Dealer ferrari to help me for dismantling, when i will be ready, he he will go to me for help, i like this because in this way him saw how i work, and if he sell for me some pieces in this way him know how do.

212Export 12-05-2014 07:17 AM

Quote:

Originally Posted by 550_Maranello (Post 515122)
HAHAHA 212, you was near to close some month ago for a maranello .... but your
Scud is great! like your other two F ....

Wait till you hear the sound .... ahahah:thumbsup:

p.s. : next sunday we will go to "La Cesarina" in Bologna ... you remember something... ?

Ahh... La Ceserina..yes I remember well !

tazandjan 12-05-2014 09:51 AM

Fabio- Very nice tool and the headers came out beautufully. May have to think about a set of those. I assume all the connectors for the original cat sensors hook up to your new cats?

550_Maranello 12-05-2014 12:38 PM

Quote:

Originally Posted by tazandjan (Post 515258)
Fabio- Very nice tool and the headers came out beautufully. May have to think about a set of those. I assume all the connectors for the original cat sensors hook up to your new cats?


Terry,
yes, all the original sensors will hook up to the new cats without cable modifications.
You can noted that i have replicate exactly the secondary air system, with open front hood the layout is exactly like the original and doing like the original.
The terminations of the two straight pipes after the cats, are fit for the coupling with the original central muffler (or central straight pipes).

Ferraridriver 12-05-2014 12:45 PM

Fabio, those manifolds exhibit outstanding work on your behalf. I only wish they would work on a 550.

Did you consider 321 alloy stainless?

Really well done. :thumbsup:

550_Maranello 12-05-2014 02:28 PM

Quote:

Originally Posted by Ferraridriver (Post 515306)
Fabio, those manifolds exhibit outstanding work on your behalf. I only wish they would work on a 550.

Did you consider 321 alloy stainless?

Really well done. :thumbsup:


Dave,
I worked on 575, but they can fit also for 550, the engine is the same F133, the only differences are following:
- different fitting for secondary air
- two lamda instead of four.
I would to produce three versions of manifolds:
1) for 550 with secondary air
2) for 575 with secondary air
3) for 550&575 without secondary air (race version)
To fit with the manifold I would to produce followings:
4) catalyzer (with lamba fittings)
5) pipe without cat for 550 (without lamba fittings)
6) pipe without cat for 575 (with lamba fittings)
7) after cat pipes for 550 (with lamba fittings)
8) after cat pipes for 575 (without lamba fittings)
The items 5-6 and 7-8 can be unified, by installing lambda fittings on all types and put plug where necessary.
Now i have prepared the pieces for three set of manifolds (prototypes) in AISI 304, i had difficult to find the commercial curves with little radius, thin thikness and good quality.
I have found one company in UK that are specialized on exhaust for formula 1, the bended everything dimensions and materials but the price start from 5-6 times and over ....
I'm considering the titanium ...
I can produce in every material,the only problem is to find the curves.


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