Lizard928

This is great information guys. Will definetly help with my intake plans.

BC

And with the right turbo sizing on your project, you could just slam the wastegate shut down low to build whatever torque you want, and then do whatever for the upper end.

So it just looks like it can be a big breadbox on top of the engine, with 8 little stubby legs. 2" OD runners equal just over the stock 1.8 inch port size.

Lizard928

That is what I am deciding, I dont think I will do a whole big box over all them, I will probably do two plenums with an equalizing tube.

and I have external wastegates with an electric controller, I dont think torque is a problem. Esp with a large displacement to start with.

BC

Here we go. Ross Machine to the rescue again.

Pre-Made Velocity Stacks for Intake Floor-placement:


Specifically made to fit the 2" pipes:



Which then can be done all connected and installed into either Thier Half Round or D-Shaped Manifold shapes:





And of course the matching Throttle body flanges:



or:

BC

The only issue is charge robbing, which probably would not be an issue with these sizes, and resonance, which can be taken care of with large tubes connecting seach breadloaf.

Lizard928

That is some pretty slick stuff there Brendan, but I think that I am going to make most of it myself and will be going with a larger plenum volume than that.

BC

I think it indeed needs more plenum volume. BUt these pieces make the "difficult part (read expensive, since I am a financial services professional, and don't weld)" at least for me, much much easier (read cheaper).

Those two loaves would need to be connected with maybe three (or four smaller) pipes between the two loaves. And then there could be two 75mm throttle bodies on each loaf front.

Hood clearance will be an issue, but cutting the hood, if its required, is, well, required. I could put a dark carbon fiber hood over the probably small area that would need to be cut out.

BC

The bases of the runners for the heads would still need to probably be CNC machined - but there is a very good chance I could do that easily on emachineshop.com if I could just learn how to do compound curves on that.

Last bit would be the mounting of the fuel rails.

But it sure looks to me that I could buy a dozen or so cool pieces, get them cut cleanly by a local machinist, and then go back to the local zuper tuner here in town that does really great welding, and I'm done.

To offset the cost, I could sell the already thermal coated intake manifold, the side plates that I had the grooves on the inner side machined off AND that are polished to a high sheen (or at least WERE), the throttle body, the nickel-freaking-plated throttle linkage.

Then I would have the whole thing probably powdercoated on the outside. I guess the inside could not properly be coated when its assembled, and you can't weld coated metal obviously, so...

90 S-4

The bases of the runners for the heads would still need to probably be CNC machined - but there is a very good chance I could do that easily on emachineshop.com if I could just learn how to do compound curves on that.

Hey Brendan,
I'd be interested in going in on that project with you, keep me posted please.
Thanks,
Joe

BC

Hey Joe. It would be maybe pretty simple to copy the outer shape of the flanges from the original intake.

THOUGH, it maybe "easier" to just make two plates with the proper holes to accept the 2" runners. Hmmm. That would add weight, but I doubt this intake will weight more than the magnesium and cast aluminum monstrosity that is the stock intake, side plates, throttle body, assembly.

What do you think Joe - should it be 8 flanges or two flanges to cover each bank?

BC

Don't you have a super duper CNC guy that you had do you your side plates extensions for your intake?

90 S-4

I'm going with a two flange's style. Then jump up to a 2- 1/16" I.D. runner
tube -- probably in the 6 to 7" long range. I'd also like to move the injectors
up a little bit from where they are now, not much just a little. I'm going to
put an as large as possible common plenum in the valley and have my TB be
located right where the MAF flange is now so I can put the factory aircleaner
assembly back on at smog time & not worry about hood clearance - clarence..
I attached a pic of the TB I'm using, it's made by AccuFab. They come in
differant sizes. Oh & my super duper cnc guy is on "year two" trying to finish
the second set of spacers that I was going to send to Todd, mine are with me.
Joe

Lizard928

I wont need to have a CNC guy make most of these pieces for myself.

I will just get the appropriate piece of aluminum flatbar and plasma cut the intake holes and grind them out to the correct size (read port match) and drill the correct hole spacing for the factory bolt holes to mount the intake. I will then weld aluminum pipes with the correct miter, I will also weld an injector bung onto each runner to get them further away from the valves. I will also have put a velocity stack on the end of the pipe to aid in flow.

I will probably create more than one of these, but will update anyone who may be interested in one when I get to it.

BC

Ah. Well, I wanted to have something like a complete car to roll on a trailer to bring to Sharktoberfest, so 2 years is a bit long for me.

To emachine shop I go. So I will see how two flanges would work out.....

BC

I can't find it in print, but there is a distinct message from a few people I have spoken to that a no stack is needed in, at least, a boosted large manifold. The runners (with a very large radius) can simply start on the manifold floor, especially when there is one entry point, and boost. It is actually supposed to be better than having the air have to find the stack. I am paraphrasing, and of course you will do your own homework, but I wanted to share that as I was concerned about this stack issue as well.

It GREATLY simplifies the assembly of the manifold.