so we've got a couple of uh corsa d vxr titanium intake pipes to make this is um one i made earlier
so we thought we'd just do a quick kind of product video whatever this will turn out to be
on the how we make it so the first thing we need to do is because of the way titanium is and
how super expensive and exotic it is um most of the titanium you'll see is pi cut like this so
it's like lots of segments of pie because it's like a slice of a pie um so the first thing we
need to do is cut some of these on the bandsaw so what we'll do is we'll mark out the tube
with a center line top and bottom so we can rotate it after each cut and then we've got
a predetermined angle and uh distance between the cuts and then we'll end up with hopefully 12 pies
which is what we need to make this uh intake then we need a 70 millimeter piece in the middle
and two 20 millimeter pieces at either end and that basically makes two 1d centerline bends
so we've got all the the pies cut now so now it's just a case of cleaning them all up deburring them
and polishing them one of the reasons these intakes are the price they are is because of the
amount of labor that goes into them they are quite labor intensive i say there's you know 12 pie cuts
three straight sections and they all need to be
deburred sanded and polished before we can start actually welding them
so the first thing i've just done is um flatten them all off on the finisher
so when we cut them you end up with um kind of like
like the grain cut through it as the saw blade cuts through
so i want to try and flatten them off and get them as flat as possible so that when
i put them together there's absolutely no gap in there so they fit absolutely perfectly together
and then of course i need to start taking off all of this bur on the outside and on the inside so
i'll do that by hand with the angle grinder and i'm literally just looking to skim off
the least amount possible off the outside just to get all these bits off
and make sure there's no kind of overhanging burr and then i'll hand deburr them on the inside
so we've got all these cleaned up now got a nice sanded finish on them all the edges are
nicely deburred so that when we put the pies on we've got literally no gap perfect to weld
up like that so now it's just a case of tacking them all up trying to keep them all as straight
as possible tacking it up as one whole piece and then we'll purge it all and weld it so we've got
all that tacked up now it's all super clean that's the most important thing about the titanium trying
to get it as absolutely clean as we can um so we get nice welds um bench is clean we've had
it pershing for a while so we've hopefully got rid of all that oxygen inside that pipe work
um clean pair of gloves and now to weld it it's probably going to take about an hour and a half to
weld this uh this one piece maybe a bit longer um so we'll set up a time lapse and see how it goes
so we've got these welded up now there was three to do so we've
welded them all that's a lot of welding a lot of cutting and uh fabrication but so the next step
for these is um these are gonna end up kind of purpley bluey but anodised so
what we need to do now is actually get rid of all of the weld so where we can
see the kind of gold colour in the weld we actually need to get rid of all that so that
and and kind of polish the uh the surface of the tube so that as we analyze it comes out nice and
shiny
right we've got it all nicely welded and polished up now so the polishing is a bit of
a laborious task with the uh titanium it's quite different to the stainless steel stuff to polish
um i guess it's because the surface is harder i'm not really sure not really a titanium
expert but um yeah so it's not just a case of giving it one final wipe down and then we'll
get the propane torch and uh kind of colour it in kind of like we do with the exhaust tips
so
ah so there we have it all um kind of anodized or burned
purple and blue it's really uh interesting process because obviously we want to try and get
it as consistent as you can um and you can quite quickly kind of go from gold purple and then blue
and so it is quite a tricky process it's trying to like build up a nice uh consistent temperature
throughout all of the pipe and and try and kind of keep the colour as consistent as possible
i think it it looks unique and that's one of the best things about these really
um you know they all will be different they all will be kind of very much handmade bespoke
um kind of hand colored in part so yeah hopefully we'll be doing a bit more of this in the not too
distant future if you've got any suggestions of uh products you think we should make
i've got a few myself a few ideas um we're going to do an astra one um we are going to do a top
pack kit that's a bit more complicated because it needs a machined flange and a map sensor boss
and i'm also thinking about doing maybe some uh coolant pipes or radiator pipes for the astro hvxr
um we're probably gonna do a titanium version of our intake for the garrett g series kit as
well so i've got a few ideas of things we can do but yeah always open to suggestions