Now that we're back with a blank canvas, the first thing needed is a proper 2in1 inlet-manifold. Ideally the runners are as short and straight as possible and are of completely equal length.
The following design is about as close as I could technically get it in the confined space available.
All of the bends are 40mm wastegate tight-radius bends. The first step was to build the Y-shaped center piece. Some careful measuring and a bit of bandsaw-jiggery-pokery goes a long way...
THIS is the kind of fitup we're talking about.
The centre-section done.
Tacked in place onto the two flanges. In order to minimize warpage, I only tacked it in four places on the one side, then on the other side and then wait until it is cool enough to touch.
Welded through. Once there were about eight to ten tacks on each I welded some short stretches. This kind of patience yielded great results. The warpage was indeed minimal and the manifold would probably even seal well without some gasket goo.
The finished product.
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