International Lancia Forums

One only has to read the excellent articles by Paul Leclercq ( http://var1016.blogspot.com/ ) to appreciate the issues with Fulvia exhausts - especially the factory manifolds and so called Group 4 versions currently marketed. It is early days but a better quality than presently available exhaust system is in development westward across the channel.

The company chosen has over 40 years of experience in developing manifolds and systems including older Maserati, Ferraris, Astons and Jaguars and even the latest Bugatti Veyron.

The basis of the manifold is my own "Gp 4" steel one (originally purchased from Peter de Wit some moons ago) and we will replace the current mid mounted side exit race system to improve ground clearance and offer standard 2 box rear outlet for those who seek quieter road legal and more original look.

To bring the cost down group buys are the best option - such a scheme has been done for Citroen DS owners and Jaguar Mk1s.

The manifold will be easier to remove than my current version.

The first stage of development will be a much more discreet race side exit version that would also suit Fulvia Sport Competizione cars. After that the manifold will be removed and jigs made and mods to ease removal with better collectors produced.

Handmade, the material will be 304 grade Stainless with vehicle lifetime g-tee. The system will suit 1300 and 1600 initially with possiblities for smaller dia. manifolds later.

Those interested in one of the following please email me so we can get an idea of numbers and hence reduce individual cost (NB: this is for all interested Fulvia owners and apart from any group discount on the purchase price there is no financial benefit my end):

Manifold only
Side exit or conventional up and over rear axle mounted box(es).
Centre pipe with expansion box
Straight pipe from manifold to rear box

Existing system pictures are posted here to give an idea of current (non ideal) setup.

http://web.me.com/ekranoplan/LUKAFOTORACING/


Kind Regards

AISI 316 is a special quality for welding, perhaps that would be better. (if the bending quality is the same)

lucasgeheniau Wrote:
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> AISI 316 is a special quality for welding, perhaps
> that would be better. (if the bending quality is
> the same)

I don't mean to split hairs, but the major difference between 304 and 316 is that 316 has Molybdenum added for corrosion resistance; all the variations of 316 (316, 316L, 316N) are commonly used in marine environments.

AFAIK, the added Molybdenum doesn't make 316 inherently better for welding than 304. For improved welding, what you really want is lower Carbon, designated by "L", which means you'd want either 304L or 316L. But bending shouldn't be a problem either way--all the variations of 304 and 316 are listed as "readily formable by bending".

Interesting project!

I have a "gp4" prototype manifold (in stainless) provided by Paul Leclerq while at evolution engineering. It is tricky to fit being very tight to wishbone part of the chassis but does align nicely to allow a bigger bore standard stainless silencer system to be retained. Ground clearance is not brilliant as my 1600HF is lowered, nor is the proximity to the lefthand side inner driveshaft point. The heat from the exhaust tends to tund the CV grease to oil over time!

On my 1600 sport I have a one off exhaust system (in stainless) with tube diameter and lengths designed for max torque at c5,500 rpm. The design is unusual as to accommodate the long lengths (and equal) of exhaust pipes before they join into one they come out in front of the front cross member before running back to a custom centre and back box. Ground clearance is compromised but for a Grand Tourer this was acceptable. I dont have the exhaust anywhere near the driveshaft joint on this car. Rolling road figures showed a healthy increase (some 20bhp) in power at 5500.

Limiting factor on all this is the fulvia head as PL has oft written about, as the exhaust valve and porting cannot be much improved.

Tim

Tim,
Is the Sport engine tuned in anyway or standard ? Thats a large increase for an engine in standard tune, but I am interested in what you have done and achieved.
Did you design it yourself ?
Thanks
Neil

Neil

Tuning wise it has what I would call Stage 2 tuning with cylinder head combustion chambers volumetrically balanced polished and ports polished. It has Holbay copy Var 1016 cams and 35mm dellorto carbs set up for 1600 engine, and the exotic exhaust I mentioned. I did not put this together but have kept it in tune and checked over the bottom end on a couple of occasions. The engine is very clean inside. Engine rebuild was 70k ago and rolling road test was 25k ago. Car has had a lot of use!

So not really a blue print engine nor racing hi comp pistons.

Tim

We used to have 304 grinded k400 for cladding of gasoline stations, but that resulted in some environments(sea industrial) in surface rust.
At that point we changed to 316 (T I believe) which solved the problem. Then I was told 316 T was a special welding quality.
Als not splitting hairs

Tokheim

lucasgeheniau Wrote:
-------------------------------------------------------
> We used to have 304 grinded k400 for cladding of
> gasoline stations, but that resulted in some
> environments(sea industrial) in surface rust.
> At that point we changed to 316 (T I believe)
> which solved the problem. Then I was told 316 T
> was a special welding quality.
> Als not splitting hairs
>
> Tokheim

As I mentioned, 316 is commonly used in marine and industrial environments (where 304 will not perform as well). But there is no 316T; what you're remembering as 316T must have been 316L, which is the version of 316 that is improved for welding because of its lower Carbon.

Thanks, sounds good.looking forward to where this thread goes.

Two years ago I had the outsourced exhaust manufacturing company used by EVO cars for their competion manifolds another batch of three stainless manifolds made. The minimum for them to restart the fabrication process after many years. Costs were around 800 euro's a piece if I remember correcty.
Connected to a nice side pipe it makes an noticable improvement over the original exhaust in my 1200HF. Or definately in noise anyway!