Well, I have fitted the tubular manifold and have a quite serious problem with the coolant hose on top of the manifold, seems impossible to reroute this without it touching the manifold. I recall in the early 20vt models there is no hose whatsoever, just a bleed point, can i just block this hole and add a bleed screw and just discard this hose? I will try to post some pics in a bit

Yes, just take that hose out of the equation.

Some pics...

http://i295.photobucket.com/albums/mm155/yogisdk/Coupe%20-%20Manifold/P1020576.jpg
http://i295.photobucket.com/albums/mm155/yogisdk/Coupe%20-%20Manifold/P1020575.jpg
http://i295.photobucket.com/albums/mm155/yogisdk/Coupe%20-%20Manifold/P1020574.jpg

I assume you mean the pipe shown in the second pic there? What you going to do about the other one that's not connected in the pictures, goes from water rail past the air con compressor to the header tank?

You can get heat shield material that I'm sure you could shape to occupy that gap, or pad it out with some of that insulating wrap.

Yes is that one in pic2
Im not sure what other hose you refer,, all is connected, except the plug to the rail and the hose it was connected to which goes back to the header tank

I meant, what have you done with the hose that connects where I've circled in red?

http://i50.photobucket.com/albums/f312/bryce_matthew/P1020575.jpg

The one circled in green is only for bleeding the system and can be removed and replaced with a bleed screw.

Oh, well i was referring to the one in red, i thought this is the one that could be removed This is the one giving the problems, I was wondering what have others done since they must have had same difficulties

I know Fergie actually had to cut his water rail in two to make his manifold fit. I believe he used some extremely high temp resistant hose to join the two parts together afterwards. As the majority of that pipe is metal, you could probably get away with the same thing.

I dont know what spec hose or where he got it from though. I'll give you his email address if you want, not seen him on here for ages.

Damn Sure, just send me his email
I was wondering if cutting the plug smaller in lenght would help, and using some 90 degree bent hose to throw the hose higher up, and then just wrapping the hose in some wrap, but damn is giving my mechanic and myself some headaches

You need one of the other types of water rail. There is a version with the output at the far left only - think it is off a non-aircon 20VT. If there aretwo take-offs it is an LE or late one, if there is one over the manifold it is an early 20VT aircon one.

Ok thanks but there HAS to be an easier solution, i refuse to remove everything again

1. blank off that feed if you have a feed at the aircon end of your fuel rail and use the piping from a non-aircon car. if you have an LE rail you should have two feeds but you only need 1. Get someone to weld a plate over it.
2. metal pipe welded to the rail
3. ceramic coat the top pipe and wrap it to try to get the temps down and also shield your coolant hose with a custom manifold cover.

The person who supplies those manifolds should tell everyone which water rail to use as you could've avoided these issues easily

It is an LE that I have
The supplier said no problem with the 20vt, even if it has A/C and all, and turbo would be in same position etc... ALL WRONG! Turbo sits not exactly in same place, the water rail is a pain now, the A/C had to be moved somewhat else could not be there, oh and now i need to SPAL fans since the original fans cant fit there no more.... HURRAAAA

where'd you get the manifold??? (just curious )

Yeah a complete pain then. And I bet it took about 3-4 hours to get all the nuts on as well

I bought it from Italy The mechanic made me promise I would NEVER recommend the manifold to anyone else, and yes John, a pain to get the nuts on, 2 hours to tighten two of them

It's a 20vt - it will always be a royal pain to do mechanical work on

Well, problem now solved, car is operational again
The 2871rs externally wastegated is completely different, the car feels much more brutal now (and the screamer pipe helps a lot also ;)) and I have only tested with 0.9 bar as I think is not adequate yet to run 1.5 bar on winter tires on a wet road

The final solution:

http://i295.photobucket.com/albums/mm155/yogisdk/Coupe%20-%20Manifold/P1020623.jpg
http://i295.photobucket.com/albums/mm155/yogisdk/Coupe%20-%20Manifold/P1020622.jpg

looks good