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Newest Project - Lower Intake Manifold for Fabricated S4 Intakes

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Newest Project - Lower Intake Manifold for Fabricated S4 Intakes

 
Old 01-04-2015, 04:26 PM
  #166  
hans14914
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These lowers were not designed to be used with stock intake gaskets. The reason being is that that the stock gasket doesnt fit that well, and you cant modify it to match. They are also tapered, grow when compressed.... just too many variables to get them to work to my standards. I have the file to have gaskets cut, and could have some laser or waterjet cut flat gaskets from more predictable gasket material.

The bolt holes in the flange have plenty of room for thermal expansion, that wont be a problem.

I like the o-ring solution best, but it does get close on the manufacturing side.
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Old 01-08-2015, 05:55 PM
  #167  
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Have the o-ring groove pretty well perfected. Its at 22.5% squish, and fits in the groove easily and retains itself for installation without any adhesive.





I think this will be much nicer than a traditional gasket.

Last edited by hans14914; 01-08-2015 at 06:21 PM.
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Old 01-10-2015, 12:02 PM
  #168  
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Here is the final design. I had to make a couple more quick edits, the largest (apart from the o-rings) was to remove the undercut that was on the bottom under the runner extension and replace it with an end-milling operation. Cost of the o-ring grooves bumped the price a bit, but I will cover this and the cost of the o-rings for these first five sets.

The O-rings that I tested were Viton, so perfect for the fuel exposure.





















Also available for those who may need it for their projects are coolant sensor relocation parts. This allows moving the temp sensor on the waterbridge used to send the signal for the dash gauge (not the critical EZK/LH sensor) to the rear driver port normally occupied by the factory block-off plate. There is also a M14 plug that installs almost flush in the
waterbridge. I needed this for one of my projects, so I made several extra sets in case anyone else needs them. Price for these two components and o-rings will be $42. A stock gasket is required for install. I have 5 sets available.











Thanks
Hans
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Old 01-10-2015, 12:39 PM
  #169  
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Hans,

I'll take one of the coolant sensor relocators.
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Old 01-10-2015, 01:27 PM
  #170  
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Me as well Hans. Thank you.
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Old 01-11-2015, 12:47 PM
  #171  
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Me too! Me too!

Thanks
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Old 01-12-2015, 12:43 PM
  #172  
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I ordered a stack of the factory gaskets for the temp sensor relocation plate so I can ship them with parts for people. Price will go up according the actual cost of the gasket and the pair of stainless install fasteners (approximately $3) but they will be ready to go when they arrive.

Also, I will be able to offer billet velocity stacks for the 2"-16g tubing. These will have the full variable radius profile for the bellmouth. I am working with the shop now to provide some additional features for easier installation in plenum materials. I will post drawings as soon as I have everything squared away.

Thanks
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Last edited by hans14914; 01-12-2015 at 01:07 PM.
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Old 01-13-2015, 08:52 PM
  #173  
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The Force is strong with Hans, I can tell.
Rock on dude!
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Old 01-14-2015, 12:40 PM
  #174  
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Here are the proposed velocity stacks, and two configurations of them installed. There are designed to be installed in a 2.125" hole in .125" thick material for easy fabrication.

Thoughts?

Thanks
Hans
















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Old 01-22-2015, 12:35 PM
  #175  
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Lower manifolds are up next week in the queue at the machine shop. If anyone else wants a set, there is still time to get in on this batch.
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Old 01-22-2015, 02:21 PM
  #176  
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Thoughts on the vstacks are:

How would these look with longer runners? Of course the short runners are for some, but for a more balanced rev range, it seems like the runners will need to be longer.
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Old 01-22-2015, 03:41 PM
  #177  
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BC,

That was just a quick mockup. The stacks are can accommodate any length. If you are talking about a longer flare, Its something I could do, but will end up costing a lot more per part.
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Old 01-22-2015, 05:14 PM
  #178  
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Originally Posted by hans14914 View Post
BC,
If you are talking about a longer flare, Its something I could do, but will end up costing a lot more per part.
And the (elliptical profile) flare will work better. I mean with a clean sheet build why not include the best proven principles at every opportunity?

http://www.profblairandassociates.co...mouth_Sept.pdf
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Old 01-22-2015, 05:27 PM
  #179  
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Originally Posted by hans14914 View Post
BC,

That was just a quick mockup. The stacks are can accommodate any length. If you are talking about a longer flare, Its something I could do, but will end up costing a lot more per part.
No, not the flare. I'm just talking about the midpipe. Just total runner length.
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Old 01-22-2015, 06:52 PM
  #180  
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Originally Posted by UpFixenDerPorsche View Post
And the (elliptical profile) flare will work better. I mean with a clean sheet build why not include the best proven principles at every opportunity? http://www.profblairandassociates.co...mouth_Sept.pdf
Two comments:

First, anyone can put whatever bellmouths on these flanges they want. Anyone can also fabricate tapered runners which have biased oval profile at turns. There's no requirement for using straight pipe or these bellmouths.

Second, the flow rates between this kind of bellmouth and one with a longer major axis of the ellipse differ by some tenths of a percent. See some testing results by David Vizard below. So while they may not be perfect, at some point the best may become the worst enemy of good.

Name:  ramch-1.jpg
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(The differences are so small that I thought they'd deserve a very small image. The full-size image by clicking or in the below link.)

http://forum.etypeuk.com/viewtopic.php?t=3394
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