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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 10-27-2013, 11:09 PM
  #91  
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Originally Posted by hans14914 View Post
Greg, you are probably right, I am jut surprised that the port matching is so extremely poor. There are likely lots of other issue which have a larger effect, but its just startling to me when compared to the quality of materials and tolerances elsewhere in the engine. I have heard that there was closer attention to port matching on the GT and CS engines.... have you seen anything to support that? Just curious.
Yes, no doubt. They ran a cutter in these intake manifolds and heads to better "match" the raw castings up, with each other. I have no data that supports this being a positive thing....but I'd guess that Porsche didn't do this because they were bored.

I've been waiting to see what Porken finds out....he's a man on a mission!
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Old 10-28-2013, 02:15 AM
  #92  
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Originally Posted by hans14914 View Post
The last four pictures are the same acrylic flange laid over a factory intake manifold, centered on the bolt holes. You can see how well the factory located the injectors, but how the intake manifold port itself is offset inwards. There is a huge ledge there that the air would hit.

I would be interested to see the effect of simply port matching an S4 engine.
Hans - take a look at the rubber intake gasket. It is angled inward inside, following the slope of the head ports.
(This is why there is a TOP to the gasket.)

On my early '88, I found the head ports to all be very close to the lower gasket opening.
Some ports on the manifold had areas that needed to be matched to the upper opening, but it wasn't nearly as bad as all of the S3 manifolds I worked on.

Gasket matching and cleaning up the trumpets did not make a significant difference in RW HP or TQ on my '88.
I felt part throttle response was improved, though. It may make a difference with larger cams and/or more cubes...

Originally Posted by GregBBRD View Post
I've been waiting to see what Porken finds out....he's a man on a mission!
A mission to drive his-self mad...


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Last edited by PorKen; 10-28-2013 at 06:03 PM. Reason: pics
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Old 10-28-2013, 07:52 AM
  #93  
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I can take a set if it's needed to make the whole thing happen.
Going to need an overseas shipment, though (I'm in Moscow, Russia).
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Old 10-28-2013, 01:03 PM
  #94  
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In Soviet Russia, intake ports you!
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Old 10-28-2013, 04:37 PM
  #95  
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So, I didnt have a chance to take pictures, but the fit is better than I could have ever imagined. The 3D print passed the fingernail drag test with flying colors. I still need to check the clearance to the waterbridge, which I will do tonight. Pictures will be up tonight, and I will take the part to Third Coast for inspection. Lets get this made, need a couple more hands, and then will collect deposits and get the tooling ordered.

Thanks
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Old 10-28-2013, 06:03 PM
  #96  
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Awesome.

Have you spoken to Greg in depth to make sure there is nothing you are doing that can work with his needs?
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Old 10-28-2013, 07:04 PM
  #97  
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Here are some quick pictures I took in the parking lot. Not sure I will have time to post good ones later tonight. I have a lot to do before heading out for Third Coast.

Hope you enjoy them.
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Old 10-28-2013, 07:06 PM
  #98  
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Injector bung

Note that there is a shoulder so the injector can not drop into the port. Also the pintle is shrouded in the casting, but the meat could easily be machined away if you wanted it to be exposed to the flow. These are also designed with the smaller bore for use with the original o-rings, not the large "S4" o-rings.
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Old 10-28-2013, 07:29 PM
  #99  
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It's too bad your 3D printer can't print that out in a plastic material that is suitable for use under the hood for an intake.

Dan
'91 928GT S/C 475hp/460lb.ft
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Old 10-28-2013, 07:48 PM
  #100  
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Wow. Really clear imaging and a way to wrap our brains around what the interaction is like.

Great stuff.

The other thread has some info about port volume. Has anyone read anything technical about injector placement? It starts to matter at higher rpms - but maybe too high to worry about here.

I am not suggesting moving yours.
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Old 10-28-2013, 10:21 PM
  #101  
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Dan,

You can create functional parts from an SLS printer. The output of the printer I have access to is very durable, but not sure I would use it for this application. I may take a look at making a flanged version and outsource the printing to an SLS house I use. I do think that the cast aluminum version is the most practical application though, as welding is required either way.

Brendan - it would be possible to move the injector higher, but there is a notch in the head that you would have go include. I do have a model that accommodates this feature, but think the factory location is fine, especially with the correct injector.
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Old 10-29-2013, 01:13 AM
  #102  
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Yes, I think we would see little benefit until after 7k rpm. And then you have packaging issues. Did you look at the injector dynamics units?
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Old 10-29-2013, 01:39 AM
  #103  
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Amazing technology Hans, really is. Its great that you get to work with it. This process is going to revolutionize manufacturing as it trickles down in price and availablity. The time in which you can go from design to prototype has been cut literally to minutes.

Looks awesome!
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Old 10-29-2013, 09:12 AM
  #104  
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This sure beats the days when they would carve this stuff out of a large chunk of butter and put in on display at the state fair.

Great work Hans. I'd be very interested in the next stage as it relates to a new/better twin-screw design with a much better intercooler. Keep me in the loop.
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Old 10-29-2013, 09:33 AM
  #105  
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Originally Posted by AO View Post
This sure beats the days when they would carve this stuff out of a large chunk of butter and put in on display at the state fair.

Great work Hans. I'd be very interested in the next stage as it relates to a new/better twin-screw design with a much better intercooler. Keep me in the loop.
you have enough power there young man!
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