Project AllegRo - EP7: Honda K20 400BHP Turbo Manifold Build: From Design To Completion!

Get ready for another exciting episode of automotive fabrication, because it's TIG time! In this video, we'll take you through the entire process of fabricating a turbo manifold for a turbocharged Honda K20 engine. We'll show you how we position the turbo and carefully plan the route for the primaries to take between the cylinder head and the collector, all while keeping the tight confines of the Allegro engine bay in mind.
In this tutorial, we'll cover everything you need to know to build your own turbo manifold, including the materials and tools you'll need, the fabrication process, and some tips and tricks for achieving the best results.
All of the components used in this build, including the 347 stainless steel collector, bends, and flanges, are available from the FabCo store. Check out the links below for more information and to purchase the components used in this build.
If you're interested in automotive fabrication and DIY projects, be sure to subscribe to our channel for more content like this. And don't forget to leave a comment below to let us know what you think!
fabco.uk/ - We sell exhaust components, check it out!

[@giggitygiggitygoofg6069]

Anyone watching here must be a " Bad Obsession Motor Sports " fan, the super kings of Bracketry . .

[@FabCoUK]

Thanks!

[@joseywales3789]

​@@FabCoUK , but there's brackets and then there's the Eiffel Tower 🗼 on its side bracket! Especially if you triangulate the three rods with thinner bar! That would certainly be an epic bracket, actually I can hear it "make the noise" of perfection!

[@julianpritchard2558]

Non technical people, and a lot of technical people, wouldn’t realise how much work goes into making a manifold. Beautiful workmanship .

[@FabCoUK]

Thanks!

[@leemidgley5394]

I could watch this guy for hours. Makes everything that I’ve ever tried to do look woefully inadequate. A bit like Alan Millyard with the work he does with motorbikes. Clever gits must have got my share of talent because I get tired just watching.

[@herenow2895]

That manifold is a work of art. Nice welding.

[@FabCoUK]

🤩

[@simonm2092]

Finish the week with an AllegRo update - made my day! Another great video 👍👍👍👍👍👍👍

[@FabCoUK]

Thanks for watching!

[@alansorbie4038]

Loving this, and the Princess build. Great to see such quality craftsmanship.

[@FabCoUK]

Thank you!

[@tonypage1056]

Love watching skilled people at work. Great job!

[@FabCoUK]

Thanks!😬

[@SimpsonsClassics]

That was a mint update, you make it look easy buddy.

[@Chamba1977]

Awesome to see this level of craftsmanship alive and kicking in the UK; top work chap!

[@FabCoUK]

Thanks✌🏻

[@stuartholmes6262]

Awesome to watch. Seeing the final product you'd think cad designed not big boys Lego 😂. Great to see proper mechanical engineering in action.

[@FabCoUK]

Thanks!

[@bigbothoee8617]

That mani has come out beautiful superb job

[@lutherblissett9070]

Beautiful welding and very nice design - you're right to prioritise nice runners sweeps above equal runner length.

[@FabCoUK]

Thanks!

[@3sheds]

Awesome, The Allegro definitely wont have respiratory issues.

[@philjames2542]

That is stunning. I'd hang that on the wall in my lounge ❤

[@FabCoUK]

Thank you 😊

[@Scoots1994]

I love the opening music.

[@FabCoUK]

Thanks!

[@mrroberts2999]

Passion in his work! Great job.

[@himwiththehair]

Lovely detail in this and thanks for taking the time to document it for all of us to watch. Nice muaic choices too, really nice to hear some fuzz on a timelapse rather than the norm

[@FabCoUK]

Thanks for watching!

[@otmuppet]

1st rate work! And your floor is clean enough to eat off!
Keep it up!

[@FabCoUK]

Thanks!

[@lestwitchen9970]

Beautiful welding, good explanations on the reasons you do stuff, goes to show all the experience required to plan out something as (relatively) unambiguous as a turbo install, great skills👍

[@FabCoUK]

Thanks!

[@leeellis6738]

Love this stuff, strangely relaxing. Top work.

[@lemmy9996]

First a video from Alex/mat/Freddy and the Stig, and now one from Adam. The day is getting better all the time!!

[@FabCoUK]

Thanks for watching 🙂

[@steveadams6183]

That manifold is lovely. Great job. Your welding skills blow me away. Love the Allegro and Princess builds. Not many other TH-camrs show builds in so much detail. 👍👍

[@FabCoUK]

Thanks!

[@southney7211]

Nice work buddy. Weld turntable looks like it saves some time and argon! 😎

[@FabCoUK]

Thanks for watching!

[@huddleberryfin]

Great work. Love a good manifold build!

[@giulianomarco]

6:51 "Jojo was a man who thought he was a loner..." 😁👍

[@FabCoUK]

🎶

[@stuartcrompton4582]

A thing of beauty

[@stephenbennett3330]

What epic welding.

[@FabCoUK]

Thanks!

[@tim205Mi]

Been around this kind of stuff most of my life, Lovin your quality work, keep your vids coming, very enjoyable, great format… thanks :-)

[@FabCoUK]

Thank you!

[@aaronbuildsa]

Watching you juggle bits of tube around made me feel much better about my struggles! I did laugh when you said there wasn't much space though.. even your starter tubes would be in my footwell 😅

[@FabCoUK]

Thanks for watching!

[@tas4976]

Quality workmanship & attention to detail as always, immaculate 👌🏾

[@raychambers3646]

If you see J S driving an allegro thats your stealth element out the window !

[@FabCoUK]

😎

[@RTC057]

So interesting and in awe of your skill. Thanks for taking the time to share.

[@FabCoUK]

Thanks for watching 😬

[@E9JMX]

I see a new 28min FabCo AllegRo upload only 7mins ago, i automatically hit like 😅😂👍🏻

[@FabCoUK]

😎

[@E9JMX]

@@FabCoUK Cool exhaust mani btw. Had a similar one made by "Crazycage" off the Ford scene years ago, for a Zetec Turbo build.

[@garysimpson8860]

It’s like watching an artist at work 👍

[@FabCoUK]

Thanks!😊

[@wilber3762]

I’m only here for the brackets. No, seriously you’re doing a brilliant job , loving every minute of it. 👍

[@FabCoUK]

Thanks for watching 😊

[@jameswaugh1134]

Great work and great content pls keep it coming

[@johnrowell942]

Fantastic work and awesome welding and manifold tools. Top skills on making it too.

[@FabCoUK]

Thanks John!😬

[@greybeered4783]

Max respect.

[@janbroechner4886]

HI.. Im a huge fan of Your FabCo channel. Not the less this Allegro sleeper project. I love it.. My mum and dad had a few Allegro´s back in the late 70s.. The Allegro were, maybe not, one of the biggest highlights in car building history.. So, turning this Austin into a Turbo beast, is just fun. It takes quite a skilled craftmanship AND Tig welder to build such a manifold, I can tell.. Really nice done. Keep up the great work..
Greetings from Denmark..

[@FabCoUK]

Thank you!

[@peteredwards7872]

Awesome work and video as always 👍

[@FabCoUK]

Thanks for watching 😊

[@bigbothoee8617]

You got enough stickout there sr

[@andrewvout9679]

A work of art!

[@FabCoUK]

Thanks!

[@davejacques2391]

Stellar work as per

[@MatthewCMaw]

This was a lot more captivating to watch than I thought it would be!! Subscribed!! 🙌🏻

[@FabCoUK]

Thanks!

[@jamiedufrayer5461]

Beautiful mate!

[@FabCoUK]

Thank you!

[@jamesdeath3477]

Surprised, but happy to see another episode so soon. Cool.

[@FabCoUK]

Thanks!

[@allantaylor392]

Fascinating process and awesome craftsmanship

[@FabCoUK]

Thank you 😃

[@theoriginalwallace]

That is beautiful, Adam!

[@FabCoUK]

Thanks!

[@BettySwollocks13]

Great video again mate, keep em coming.

[@FabCoUK]

Thanks 😊

[@aidencoder]

That was so cool. I've always wanted to see the process of making an exhaust manifold. Thank you for the detail!

[@mrmawson2438]

Great video mate

[@FabCoUK]

Thanks!

[@artiefufkin3292]

Outstanding work. A joy to watch, you make it look easy, which is the sign of a master craftsman

[@jamest5149]

Awesome work as usual. Great video and series 👏

[@FabCoUK]

Thanks for watching 🙂

[@bobthesnobscotland2821]

Cheers. Great job

[@FabCoUK]

Thank you

[@tonydotnottingham]

Really awesome seeing the progress of this build - keep up the good work!

[@FabCoUK]

Thanks!😊

[@rodsantos9325]

Fantastic workmanship, mate. 👍

[@FabCoUK]

Thank you!

[@Oldenroadie]

Awesome ... appreciate your commentary explaining what and why you are doing what you are doing

[@FabCoUK]

Thanks!😊

[@Anderzander]

It’s a think of beauty!

[@FabCoUK]

Thank you!

[@mlowbridge2988]

Some of the best custom work in the world,great video

[@FabCoUK]

Thank you!

[@pda49184]

Brilliant fabrication. Your welding skills are awesome..

[@FabCoUK]

Thanks! 🙂

[@grahambaker9377]

Superb skill on show awesome finished product.

[@FabCoUK]

Thanks!😃

[@dcallan812]

Nice work. great update 2x👍

[@FabCoUK]

Thanks!😬

[@dcallan812]

@@FabCoUK 👍👍

[@brendonhearn8778]

Extra nice. A big job, squished into 28 mins. Looks the "Ducks Nuts"!!!

[@FabCoUK]

Wish I could make it in 28 minutes that’s for sure🤣

[@AshleyCaunt]

Love to see the process Adam, incredible work as always dude 😍

[@FabCoUK]

Thanks ✌🏻✌🏻

[@rstvan]

Your fabrication skills are a pleasure to watch 👌👌👌

[@FabCoUK]

Thanks!

[@johnhaynes9910]

Impressive welding skills - in awe :)

[@FabCoUK]

Thanks😁

[@TruckerMRB]

incredible welding...Excellent

[@FabCoUK]

Thanks!😁

[@woznaldo]

Johny led me here but, I’m very happy that he did! Lovely work and great explanation. You mentioned you’re using 347 SS pipe but, what size/dia?

[@bigchopper14]

I wish i was that clever, amazing to see what skill goes into making a manifold from scratch, great video

[@FabCoUK]

Thanks for watching!

[@MOTORSPORT401]

Awesome work

[@FabCoUK]

Thank you!

[@backupintheday9710]

Top skills on display.

[@FabCoUK]

😁

[@backupintheday9710]

@@FabCoUK Tidy work. I look forward to seeing this build completed.

[@andybegbie8553]

Great video, just want more, lol. Princess or allegro, not bothered which. Keep up the good work (just more, lol)

[@FabCoUK]

They’ll come as fast as I can. This is just a hobby 😊

[@andybegbie8553]

Not a criticism, just like the videos. Keep doin em 👍

[@dave.harmon]

Allegro, princess and a mini.
You'll get yourself a reputation like that 😂

[@FabCoUK]

😃

[@Tuscanvince]

Nice job! 👌

[@FabCoUK]

Thanks for watching 😊

[@cconcannon5145]

Bonkers. Love it. Could you do a 'shed build Spitfire Mk. V' next? And put an extra big supercharger on it??

[@FabCoUK]

Couldn’t get out of bed for a Spitfire, sorry!

[@cconcannon5145]

@@FabCoUK I meant the plane, not the Triumph btw!

[@alexmacdonald4270]

A genius a work

[@FabCoUK]

😅

[@oldieman730]

Beautiful work. Makes me think I should go learn to weld.

[@FabCoUK]

Give it a go!

[@jonmorris518]

Weight watchers! 👍

[@michaelhodgson3833]

So, had a great party weekend getting "daft" thanks to some "random" guy getting a new shiny hat, I was thinking, maybe they should have given it to you ?, after all you do have a Princess, 😅 Another great episode, thank-you.

[@FabCoUK]

I don’t just have ‘a’ Princess, I have THE Princess ;)

[@michaelhodgson3833]

A good point & well made 🤔 !, I know which one I'll be watching ....

[@stephengirling7859]

Quality!

[@FabCoUK]

❤️

[@yamlikhaharias9244]

Awesome

[@FabCoUK]

Thanks!

[@johnnunn8688]

Here’s an idea. How about using a suitable lump of memory foam, or similar, to hold the turbo In position? That should leave both hands free to position bars and brackets.

[@FabCoUK]

It could work potentially yeah!

[@markthompson9914]

Jonny should be chuffed with that work of art, I would be 👍✌️

[@FabCoUK]

Thanks 😊

[@markthompson9914]

@@FabCoUK
Any idea of a time frame for either the cheese wedge or the agro ? and are u doing this on your own, a one man band as such ? ✌️🇬🇧

[@howardalexander0621]

A work of art. How many hours to design, mock up, test fit, weld, check fitting again and finish welding?

[@FabCoUK]

About 15 hours work

[@lestercranmer2631]

you may be hearing from Paul McCartney's lawyers 😆 6:50

[@FabCoUK]

🎶

[@fiatbandit]

OOH my good you are so SLOVEEEEE

[@FabCoUK]

whats a 'SLOVEEEEE'?

[@_Brad_D]

Great work, thanks for sharing.

[@FabCoUK]

Thanks for watching!🤩

[@IrenESorius]

👍‍‍😎👍

[@FabCoUK]

✌🏻

[@jeremystone6613]

So how long did you spend on it? It looks fantastic!

[@mikewilliams6467]

Skookum as frig as ever

[@FabCoUK]

Good enough for the girls I go out with!

[@ollieguyon]

Your attention to detail is impeccable sir! I wonder if you’d be interested in doing something similar for my VW Golf mk1 20V turbo swap?

[@FabCoUK]

Not taking on anything else currently, sorry!

[@GeorgeEI7KO]

are those 'Lego' thingies expensive? Beautiful work man!

[@FabCoUK]

Depends how much money you have!

[@GeorgeEI7KO]

@@FabCoUK Ah, that answers than then lol

[@user-uh6yd6sj7h]

круто!!!!!!!!

[@FabCoUK]

😎

[@misterhughes.2935]

I've always been under the impression each branch needs to the same length so there isn't uneven pressure across the cylinders, is that not an issue with turbos?

[@FabCoUK]

Makes next time no difference on a turbo car. If I was building a race car it’d be a consideration, but this is simply a road car

[@koolerking440]

This is a stupid question, but the exhaust manifold is going to a junction in the output of the turbo, right? Is that normal?

[@FabCoUK]

The exhaust manifold feeds the turbo inlet 😊

[@bannerzone_UK]

Do you realise you've got a race of time with @Retropower and there Allegro now. Especially as they're both Honda Engines. Even better, some 1 to 1 races etc when they're both done.

[@FabCoUK]

There’s no race against time. It’s done when it’s done 😌

[@hoekmrb]

Why no video on how you got in there between the pipes to weld them to the collector.. or atleast the last pipe...!

[@FabCoUK]

Can’t film everything, sorry!

[@mrmawson2438]

Hello mate

[@FabCoUK]

👋🏻

[@benbuchanan672]

Is there no benefit to making turbo primaries equal length, or is that a constraint too far?

[@FabCoUK]

There’s much less of a benefit on a turbo application, and it’s just a road car after all.

[@phrayzar]

How's the Princess going?

[@FabCoUK]

Haven’t touched it in a few weeks!