Exhaust development
Crafting Precision: The Story Behind Our Exhaust Manifold Design
When we set out to design our exhaust manifold, we wanted more than just a part that fit the engine bay, it had to embody durability, precision, and performance. Through thoughtful engineering and extensive testing, we’ve crafted a manifold that not only meets but exceeds the needs of Volvo enthusiasts worldwide.
The photos in this article provide insight into the challenges we faced while designing our exhaust manifold. To start, we 3D-scanned the engine bay, long block, and cylinder head, allowing us to create initial designs with the desired flow characteristics. However, while 3D design is an excellent tool, real-world prototyping is essential. Using 3D-printed PLA mock-ups, we discovered multiple fitment issues once the fully built engine and accessories were installed. These included challenges with the alternator, cooling pump hoses, and variations between different RedBlock models.
Dyno Results of the finished product are coming soon with another technical update.
Material Quality: Why 347 Stainless Steel?
At the heart of our design lies 347 stainless steel (SS) a material celebrated for its exceptional resistance to heat, corrosion, and thermal fatigue. Engineered to withstand the harshest conditions, this stainless steel alloy ensures long-term durability, even in the most extreme environments.
What sets 347 SS apart is the addition of niobium, a stabilizing element that minimizes the risk of cracking over time. This enhancement allows the manifold to endure thermal cycling and high-pressure conditions without compromising its integrity.
Beyond its resilience, 347 SS is easily Tig weldable, offering flexibility for future modifications. Whether you're planning to update wastegate flanges or adapt to a different turbo configuration, this Material ensures adaptability as your build evolves.
for more on material science check out our technical file.
Design for Optimal Flow and Firing Order
Our manifold is designed to complement the firing order of the Volvo B230 engine with a B234 16-valve head. This optimization ensures that each exhaust pulse merges into the turbo uninterrupted by the previous firing cylinder.
While such optimization may be challenging to measure in real-world conditions, the results speak for themselves: even scavenging, balanced air-fuel ratios, and a smoother-running engine. This design promotes reliability and performance, offering a setup that feels as refined as it is powerful.
The internal runner size plays an equally critical role in this performance. Carefully considered to maximize exhaust velocity while avoiding tight-radius bends or restrictions, the runners ensure that the manifold is never the limiting factor in your system. Instead, the most significant restriction becomes the turbine housing A/R a choice left to the customer, allowing for tailored performance.
Turbo and Wastegate V-Band Fitments
Modern turbo technology demands modern solutions. Our manifold is built with a Garrett V-band fitting to support G25, G30, and G35 turbos, as well as the GTX30 and GTX35 series. Designed to accommodate the largest turbine housing in the G30 range a 1.21 A/R. this choice futureproofs the design for the next generations of Vband turbos
Boost control in high-performance applications is best achieved with an external wastegate, but its size posed the main challenge in ensuring proper fitment. We focused on maintaining wastegate priority while adjusting the design to work within the tight confines of the engine bay.
The Turbosmart Hypergate WG45 45mm wastegate flange placed for exceptional wastegate priority, This is the most common issue with aftermarket manifolds, you get on the dyno and experience uncontrollable boost creep due to an unfavourable location of the wategate. Not with our design.
For those exploring garrett turbo alternatives, we advise customers to verify V-band sizing and compatibility with the turbo manufacturer (Turbosmart make some quality options), But when considering replicas or lower-cost alternatives do your research. (pulsar for example)
Solving Spatial Constraints
Fitting high-performance components into compact spaces is no small feat. Designed for the Volvo B230 engine with a B234 16-valve head, it utilizes the original slanted engine mounts to maintain a clean and functional fit.
We’ve tested this manifold in one of the tightest Volvo engine bays a right-hand drive Volvo 240. Addressing critical spatial challenges such as the strut tower, frame rail, steering linkage, brake booster, oil filter, and alternator. it took many revisions to get this right but the result is a seamless fit that eliminates guesswork.
For right-hand drive models, the only component requiring relocation is the clutch master cylinder, which can be repositioned under the dash for a sleek and functional setup. (relocation kit comming soon) The manifold is compatible with both the 75A alternator from the Volvo 240 and the 100A alternator from later Redblock engines, ensuring versatility across various configurations.
The easy option would have been to place the turbo further forward, away from the cylinder head, to gain additional space. However, this approach often requires deleting factory components like the washer bottle, coolant overflow, and radiator shrouds, while potentially forcing users to switch to an electric fan. While this might be acceptable for a race car, our priority was to create a product that could be used on a street car, retaining all the conveniences like washer fluid and proper cooling systems. By positioning the turbo where it is, we’ve maintained compatibility with factory components while ensuring durability, performance, and a straightforward installation process.
The V-band allows for clocking the turbo in whatever way your chosen turbo fits best in your engine bay
Beyond compact spaces, the manifold also fits larger engine bays like those of the Volvo 740 and 940. For customers using upright engine configurations, we can provide measurements to confirm hood clearance, ensuring the perfect fit for your setup.
The Result: A Quality Performance Manifold that is truely bolt on.
Ando Engineering believes in engineering solutions that respect the heritage of classic vehicles while enhancing their capabilities with modern technology. This manifold isn’t just a part it’s a reflection of our dedication to performance, durability, and thoughtful design.
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