Flange - I can get you a translation if you tell me what language you would like it in.

 

Mmmhhmm. I think I just look hard at the details to make more eloquent solutions. You should see my prose. I always got published, but I was always asked by the editor to "Cut some fat"

 

Brendan, I have a local fellow that I can get 50 or 52mm Jenvy ITBs, 8 of them (as suppose to the duals Louie used) for $2k, but then making a flange etc can be pricey.

 

French.

 

Isn't "Flange" french?

Well, How about this: PLAQUE en métal

 

The flange should be relatively inexpensive if you keep the design simple. Use the drawing you posted several pages back. "Extrude" the part so it is slightly thicker, enough room to allow translation of the non-standard porsche port to say the oval tubing sold by RMR. Then create two separate drawings from here. In one drawing place the intake bolt holes and the smaller of the two port shapes centered on the flange. You can then flatten this drawing to 2D if you prefer, as this will go to the waterjet cutter.

On your second drawing, you start with the basics of the first. So you have a thick flange with some holes cut strati through it. From here you add the second, larger port size (either on the top or bottom of the flange, depending if the runner is larger than the port. Then sculpt the transition of the port size to the runner size. On the opposite side of the flange, design your recess for the runner, as you show in previous drawings.

Using this 2-stage process, you have most of the heavy cutting done on the waterjet, which is much less expensive. Then your multi-axis matching is only to create the port match and runner relief. Last set of flanges i had cut were for a turbo manifold in 321SS, and the material and labor was around $300 for the exhaust, wastegate, turbo and downpipe flanges. I would imagine your cost would be similar for two intake flanges. The multi-axis machining would be pretty quick. I dont see getting that bill too high either. My assumption is that you could probably get both flanges done material included for around $500.

Hans

 

A "plaque" can be anything.
Translation of "plaque" would be metal plate.

So, it's just a link between the cam port and the intake manifold?

 

Its flat (or mostly flat) plate that the end of the runners are welded to so they can be attached to the port on the head.

 

Okay. trying to map through what you are saying. But what about the fact that I want the part to be somewhat angled at the top so as to accept straight runner tubes instead of having to have the runner tube cut at an angle?

 

If you want the angle to be in the flange and not on the runners, then yes, the above would not apply. How many degrees of angle are you looking for. Waterjet loose their tolerance on thick cuts. I have heard that it is possible to cut aluminum 2" or thicker with average commercial waterjets, but not sure i would expect tolerances at that point. I think perhaps you have engineered yourself in a corner.

What exactly is the reason you dont want to cut the runners at an angle?

 

Because the runner would then become "oval" and it would need to be but welded to the flange. Its just another step that I cannot be sure that I can trust to someone around here. I think a good compromise between my ludicrously complex but very pretty design with the round runner interface on the flange WITH the injector bung, and a flat flange is very similar to the one that Sterling shows in his post about "stage 2" - but I will not be bolting the TB on there - this will be a non-ITB manifold.

BUt your idea and the idea of some personal communications make perfect sense. Keep it simple stupid (to me). This way I can deal with the issues of atomization better with those injector bungs higher up the runner - as I have read that the larger the injector, the more time it needs to properly atomize - people say I can't just shove a 160lb injector right near the valve backside where a 19lb one was there before and expect it to run smoothly.

Location of the injector is not critically important, it just seems to make difference when they get big:



Caption on this pic reads:
But more towards my requirements (10,000rpm Small block V8 above? Jesus) Anyway, more down to earth:


Caption reads:
http://www.hotrod.com/pitstop/hrdp_0...ion/index.html

 

I have redesigned the original piece to reflect the advice given here and in PMs. Thanks to all who suggested things - I appreciate the input as I am very willing to learn, and grow.

How about this?

 

Anyone know how to take metal away from the areas that connect the ports? I did this with a 20 degree plane offset from the center long axis.

 

Brendan, like this? This was pretty damn easy. And low cost.

Hammer