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HOW TO: DSM turbo manifold on a Saturn

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  • HOW TO: DSM turbo manifold on a Saturn

    Well, since we had a thread that we need more articles, here's a quick one.
    I just got done adapting a DSM cast iron manifold to my 5-bolt 2nd gen DOHC head.

    A few common things about DSM manifolds:

    - If you have a 3rd gen, all you need to do is possibly drill out one or two holes. That's it. There should be no guide for that because it's basically a bolt-on.
    - If you have a 1st or 2nd gen, follow this guide.
    - DSM manifolds only fit DOHC S-Series engines, I don't know about SOHC, and you shouldn't even be having those thoughts.


    Here we go. This is how the FelPro gasket lines up to the manifold. In reality, the ports on the head are smaller and line up pretty damn good:


    This is what you want to cut off from the manifold to make it bolt up:




    5 minutes later:


    Save these tabs. Certain manifolds you don't have to, because they have extra material to drill the top holes in. This one didn't. You'll use the tabs to make the top bolt holes:


    Reverse the tabs and weld them up to the two spots where you will have bolts. You will not need to drill the tabs, they line up perfectly:


    Here it is with the tab welded from the back. You'll want to make sure your welds are good. Also, make sure you don't try to make the tabs "flush" with the surface. They don't need to seal, they just need to keep the manifold attached. If you make them "flush" you're running into a possibility of them sticking out a bit, and it will not make a good seal. Of course, it all depends on your skill level:

    /\ For my purpose, because my head is actually port matched to the bigger FelPro gasket, I decided to port out the manifold some. I didn't care about smoothness, so that was the result.

    That's it! Bolt it up and enjoy:


    There are many varieties, and if you get the shiny eBay kind, make sure you weld metal support tabs under where the pipes connect to flanges, specifically where the wastegate flange goes into the collector. Most manifolds already come with those tabs, but some might not have ALL the necessary tabs in place. Otherwise, these things are pretty sturdy, just don't spill coolant on them when they're hot!
    2000 SL2 5 speed, boosted, meth injected, parted out...268whp & 254wtq (stock pump maxed out)..

  • #2
    Re: HOW TO: DSM turbo manifold on a Saturn

    very very clever.
    CSW Tuning or Facebook!
    - Stork

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    • #3
      Re: HOW TO: DSM turbo manifold on a Saturn

      wow nice job

      no realy nice

      Comment


      • #4
        Re: HOW TO: DSM turbo manifold on a Saturn

        Nice work Chinaman.

        Comment


        • #5
          Re: HOW TO: DSM turbo manifold on a Saturn

          Nice Job!
          Jeff W.
          Old Fella Nobody Remembers

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          • #6
            Re: HOW TO: DSM turbo manifold on a Saturn

            WG location kinda sucks...other than that seems like it'll do the job. Weight difference?

            -RD
            TOY: 95 SW1 Turbo 5 spd DOHC swapped - Sold.
            DD: 04 ION Redline (stock)

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            • #7
              Re: HOW TO: DSM turbo manifold on a Saturn

              congradulations yuri, you made a meaningful post that will end up in the tech section for the rest of this sites life!

              lol

              seriously though, good write up
              Black 2006 Cobalt SS/SC
              ZZP | GMPP |EBC |GM Stg2

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              • #8
                Re: HOW TO: DSM turbo manifold on a Saturn

                Thanks guys. The WG location on this one is pretty stupid. It barely clears, though with some slight modification (or a smaller wastegate) it was not an issue at all. My biggest problem is that I didn't have time to finish the pipe that connects the WG to the downpipe. My friend welded it at a crazy angle, but it was late and we couldn't buy more supplies. So at the moment I can't put a filter on the turbo.

                I did mess with the wastegate, so I'm boosting something like 15-17 psi right now, and I fucked up my t3/t4 gasket, so I have an exhaust leak where the turbo connects to the mani. It's hard to say at this point how bad the boost creep will be.

                I will say a few things about this cast iron manifold though. It's nice, it's rather heavy (but right around what a stock saturn manifold weighs, maybe a tad lighter), but it's definitely indestructible, and the diameter of the pipes seemed bigger than my old shiny manifold, which was a nice surprise. It makes the car a whole lot quieter, and when it warms up it brings up the spool quite a bit. Overall, it was worth the $200 bucks and wasn't all that hard to attach to the car. Really you just need a grinder, even if you don't have a welder just bring the tabs to a local muffler shop and ask them to weld it.
                2000 SL2 5 speed, boosted, meth injected, parted out...268whp & 254wtq (stock pump maxed out)..

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                • #9
                  Re: HOW TO: DSM turbo manifold on a Saturn

                  Is that a treadstone manifold? Sorry to highjack.

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                  • #10
                    Re: HOW TO: DSM turbo manifold on a Saturn

                    Treadstone? No my manifold is chinese. Unless treadstone is some chinese brand. But no, I'm pretty sure my manifold is made by SBC (Some Basement in China).
                    2000 SL2 5 speed, boosted, meth injected, parted out...268whp & 254wtq (stock pump maxed out)..

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                    • #11
                      Re: HOW TO: DSM turbo manifold on a Saturn

                      good writeup ChingChong....finally giving us something usefull ehh?
                      1995 Saturn SW2: Crushed
                      1995 Saturn SW2: Lower Than You


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                      • #12
                        Re: HOW TO: DSM turbo manifold on a Saturn

                        You really shouldn't need a gasket between turbo and manifold if both flanges are good. I had one of those stainless one between mine and I actually cracked it and it leaked. Threw the gasket away and now run without one and that is the only place that doesn't leak.

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                        • #13
                          Re: HOW TO: DSM turbo manifold on a Saturn

                          You serious about the Treadstone being Chinese commmet?

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                          • #14
                            Re: HOW TO: DSM turbo manifold on a Saturn

                            Originally posted by scottyr94
                            You really shouldn't need a gasket between turbo and manifold if both flanges are good. I had one of those stainless one between mine and I actually cracked it and it leaked. Threw the gasket away and now run without one and that is the only place that doesn't leak.
                            You know, that's what I did with my old turbo and it was great!
                            I might try it. I ordered the gasket anyway, but I will run it without one until the new gasket arrives and see how it goes.
                            2000 SL2 5 speed, boosted, meth injected, parted out...268whp & 254wtq (stock pump maxed out)..

                            Comment


                            • #15
                              Re: HOW TO: DSM turbo manifold on a Saturn

                              YAY
                              [quote author="shortbus"]Stage 2 is great. Its covered by warranty, better fuel economy, the eaton screams louder so deer wont jump onto the road, it makes girls get wet, and the emissions produced will not kill songbirds or melt glaciers.[/quote]<br />[quote author="retardpartol"]...who is sober and noton any kind of intoxication whether is be ibuprophin[/quote]<br />LSJ phun

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