Rennlist - Porsche Discussion Forums - Newest Project - Lower Intake Manifold for Fabricated S4 Intakes

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Looks like my -10 will be fine too.

Here are pics of the test print. Injector fits (can see how tight it is to get it in there and get a nice entry angle).

I will test it on a head tonight when I get home.

https://cimg5.ibsrv.net/gimg/rennlis...4b4325936d.jpg

https://cimg6.ibsrv.net/gimg/rennlis...756492ab43.jpg

https://cimg7.ibsrv.net/gimg/rennlis...9eb5b92c4f.jpg

https://cimg8.ibsrv.net/gimg/rennlis...d7bfd51b07.jpg

https://cimg9.ibsrv.net/gimg/rennlis...138f503bf8.jpg

Did you ever mock up with injector dynamics model injectors? They are basically the mini bosch.

thats a nice print, what printer+slicer are you using

https://cimg5.ibsrv.net/gimg/rennlis...a070fd158d.png
The InjectorDynamics use a Bosch EV14 housing.

More info on this injector format can be found here:

http://www.bosch-motorsport.de/en/de...s_1_171028.php

The injector bore is 17mm, as the EV12 is 15mm.

The only problem with an EV14 and this lower flange design will be the small locating nub. It does interfere with the injector bore slightly. You can see how little it protrudes past the outside surface in these renderings. A quick brush with sandpaper, and they would fit just fine.

Image 5 shows just the piece of the locating nub that would interfere, and its thickest point, it is 0.05mm which is half the width of a human hair. Of course there may be manufacturing differences that would increase this, but quite literally a single pass of sandpaper should give enough clearance, or several would get plenty of room.

Regards,
Hans

https://cimg1.ibsrv.net/gimg/rennlis...ef96489f2a.png

https://cimg2.ibsrv.net/gimg/rennlis...14603980f5.png

https://cimg3.ibsrv.net/gimg/rennlis...9a74d46322.png

https://cimg0.ibsrv.net/gimg/rennlis...d4acb1a2f2.png

Than you. He specs them in many different configurations, so I feel like its perfectly workable. He has worked with Bosch to create a somewhat modified 1300 with all stainless parts. I hope that's not just marketing. At normal pressures, 1300 is the perfect size for 800hp and alcohol.

Its interesting how he shows the nubs on the real pics, but the dimension drawing does not.

http://injectordynamics.com/injectors/id1000/

BC- You will be fine as long as you are alright "kissing" your pricey injectors with some ~350grit.

To all others, please note that compact injectors ARE required for this design. EV12 is optimal, and as shown above, EV14 will fit with a 10second modification. Modern "smooth-bore" Siemens Deka injectors also will work fine.

As mentioned above, the injector pocket bore is 17mm so make sure your injector will fit in that footprint if its not in the above list.

FYI- the blue Bosch 0280156127 injector, as pictured in the test part, is a nice ~40lb high-impedance injector with a split-spray pattern ideal for our port configuration also shown here:

Regards,
Hans

Can you mock the - 10 rail in your drawings? It's the RMR ones.

Quote:

Originally Posted by BC (Post 11922528)

Can you mock the - 10 rail in your drawings? It's the RMR ones.

BC - I made a quick mockup (nothing postable) but the RMR -10AN rail stock will work just fine for most configurations. You start running into interference with a 22.5deg bend at 3"CLR. So, if you are planning on vertical stacks, the rail will touch the runners if using 3"CLR. If you go larger on the CLR or bend less than 22.5deg (with a 3" CLR), there is no clearance problems at all.

I am glad to say that we reached the 5 sets, funds have been collected, and files are going to the shop Monday morning.

I made another round of edits this morning to try and add O-ring seals to the flange both sets of files are going to the shop

Here is a quick preview:

https://cimg4.ibsrv.net/gimg/rennlis...75027ce089.png

https://cimg3.ibsrv.net/gimg/rennlis...f6718e431d.png

https://cimg5.ibsrv.net/gimg/rennlis...2102ce8cc6.png

Are these intake manifold flanges intended to be run with or without the stock intake manifold gaskets, or either way?

The reason why I am asking is that the stock intake manifold gasket is thick and reinforced. It will hold against a lot of manifold pressure while still providing enough compliance for thermal expansions. If one is using the stock intake manifold gasket, then one can "just" weld the manifold together and not worry about the block and heads expanding slightly differently from the intake manifold.

If one however uses the O-ring seals and bolts the intake manifold directly on the head, one has to at least think about the thermal expansion and the stresses. Likely one will have to build in some compliance into the intake manifold such that it will not crack over time. The benefit from having an O-ring seal is that one can locate the intake manifold precisely relative to the head. Does the stock intake manifold have dowel pins for location, I don't think so? By adding those dowel pins, then one could really precisely port match the manifold to the heads for the best flow.

Both solutions work. From memory, Simard's ITB uses O-ring seals and Todd's turbo manifold uses stock intake manifold gaskets. Both setups have managed to make some serious power.

For these flanges, the ability to use either the stock gasket or an O-ring seal to the head would of course be the best option. The bolt on solutions would use the stock gasket and more hard-core builds could use the O-ring seal.