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Newest Project - Lower Intake Manifold for Fabricated S4 Intakes

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Old 11-16-2015, 02:21 PM
  #241  
hans14914
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Fuel rail parts are back. Here is one of the -8 rails (tapped for ORB fittings) The stainless retainer tabs are also keyed to hold injectors in the correct clocking if they have a twin beam spray pattern.

I think I have 10 sets ready to go for those who want them shipped with their flanges.



























Old 11-16-2015, 02:38 PM
  #242  
BC
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Those look great. You will send Together?


Originally Posted by hans14914
Fuel rail parts are back. Here is one of the -8 rails (tapped for ORB fittings) The stainless retainer tabs are also keyed to hold injectors in the correct clocking if they have a twin beam spray pattern.

I think I have 10 sets ready to go for those who want them shipped with their flanges.



























Old 11-16-2015, 03:41 PM
  #243  
Tom in Austin
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More inspired work ... can't wait to see what kind of designs people think up to make with these starter pieces ... maybe a v-mounted supercharger?
Old 12-08-2015, 01:18 PM
  #244  
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OK. These are now ready for shipping. Eveyrthing instock and ready to go for those that pre-ordered. Future sets will be available at a higher cost, but leadtime should be around 3-weeks start to finish.

If you would like to upgrade your order to include rails or a coolant sensor relocation kit, I have those on hand as well.

Please contact via PM and we will get shipping sorted out.

Thanks
Hans
Old 03-17-2016, 05:22 PM
  #245  
hans14914
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One set is available from the first batch if anyone wants to make their own manifold before the driving season starts. Send a PM for more details.
Old 03-18-2016, 07:16 PM
  #246  
Jerry Feather
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I'll take the set. Thanks Hans.
Old 03-20-2016, 03:30 PM
  #247  
Jerry Feather
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Hans, you mentioned a couple of times or more in this thread about "off-the-shelf mandrel bends" that will work with these flanges. Whose Shelf might they be off of?
Old 03-21-2016, 10:50 AM
  #248  
hans14914
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2" Mandrel bent tubing is pretty common. There is likely someone in your area that can supply you, but one of the most cost effective online suppliers is Columbia River - http://www.mandrelbends.com/

The exit angle is 22.5 deg (relative to the ground plane) so for a vertical or horizontal exit, split a 45deg bend in half and rotate it accordingly.

Regards
Hans
Old 05-08-2016, 06:26 PM
  #249  
Jerry Feather
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Hans was great about sending me the last of this batch of his beautiful intake bases. They really are. I wanted these to form a basis for the intake I need to redesign for the engine that I'll be putting in the Radical Custom 928 that I hope to do over the next several months. With the 2 inch section planned for that 928 I need to lower the stuff on top of the engine and that translates to a lower induction. I'll be doing all of this with an S4 so I will need something to replace an S4 intake, but overall two inches lower.

So far I have kind of decided on intake runners out the top of the Hans bases and running up and over into an intake plenum. I hope to retain the S4 throttle body under the intake so that and the Hans bases pretty much will dictate the floor of the box. I have also decided to try to use some 6061 aluminum mandrel bends that are bent on a centerline radius of 3 inches. All 8 runners will be equal length, and about 6 and 3/4 inches long above the bases, but the bend will come at a different height from the base since the back of the intake box will be two inches taller than the front, just as with the original, just lower. The bell mouth inlet will be in addition and about 3/4 inches deep.

I don't have my mandrel bends yet, but I went ahead and made myself some of the bell mouths out of some 3/4 inch stock I had around here. I haven't figured out just how the inlet tubes and bell mouths are going to nest together in the plenum, but I'll work on that as I progress. It looks like this intake is going to be pretty much an organic process, since I don't actually yet have a good image in my head about the base, the sides, front or back, but I do have a picture of what I want the top to look like--in my head, that is.

Here is a bunch of pictures of the progress in making 8 bell mouths:
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Old 05-08-2016, 06:30 PM
  #250  
Jerry Feather
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Oops, I skipped the one showing using sandpaper after the file.
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Old 05-08-2016, 06:46 PM
  #251  
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http://m.ebay.com/itm/261247834851?_mwBanner=1
Old 05-08-2016, 06:55 PM
  #252  
Jerry Feather
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Yes, I know. That's for you guys who didn't take the shop classes, so you can't do it for yourself.
Old 05-09-2016, 03:39 AM
  #253  
Strosek Ultra
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Jerry, your bellmouths looks good. It is good to have a lathe being able to fabricate velocity stacks in any custom design to make it fit where ever you like. Here pictures of one I made for flow testing. Made out of a solid bar of aluminum.
Åke
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Old 05-09-2016, 09:06 AM
  #254  
Jerry Feather
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That's cool, Ake. I wonder just how far out from the central bore/hole the shape stops making any difference.
Old 05-09-2016, 10:10 AM
  #255  
Chris Lockhart
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Jerry and Ake, beautiful work!


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