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VW/Audi 07K (2.5L 20V I5) Swap Thread

 
Old 09-20-2018, 06:09 PM
  #391  
senior_squishy
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I'd agree with the others, carbon fiber would be cool, but I'd worry about how it would stand up to high boost and heat from the engine.

Also agreeing with the longevity of the intake; All these options seem viable when it comes to the structural integrity, but I'd like to be able to daily something like this. So more than one option would be nice.

Looking good other than that. I'm thinking welded would be the easier option considering the tooling requirements for cast aluminum are more involved.
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Old 09-21-2018, 09:56 AM
  #392  
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Originally Posted by V2Rocket View Post
photos can be deceiving but...
there's maybe 1" between the "runner/plenum plate" and the TB inlet. plenum plate looks symmetrical.

run a bandsaw down the middle, flip the plenum around, weld back together?
I like that idea, and was actually planning on doing that up until last week. IE sent me a dimensioned drawing of their intake, and unfortunately the runners are a couple inches too long for that to work on a 944 (not enough room to clear the brake booster). The other problem is that the throttle body mount would stick through the 944 hood.

On my design, I shortened the runners and angled the throttle body mount down to clear the hood.
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Old 09-21-2018, 05:10 PM
  #393  
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Anyone have a throttle body recommendation? I think it would be good to have one with an integrated TPS which is compatible with at least some of these engine management systems: VEMS, Megasquirt, Electromotive, AEM, Bosch, Motec

I'm looking at this one, made as an upgrade for a 302 or 351 ford mustang or lightning. This one is 80 mm, but they are also available in 70 mm if 80 is too big for some reason. It has a TPS built in, and has a place to bolt on an IAC motor. https://www.summitracing.com/parts/bbk-1514

Last edited by vt951; 09-22-2018 at 11:19 AM.
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Old 09-22-2018, 02:06 PM
  #394  
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I have been following this thread with interest. I have six different forms of 944 , am boat building in composite and have dabbled in parts for Porsche. With the advance in drawing we now have compared to my skills as an old timer with little computer skills this project may be something that I can help with. When it comes to oil pans, intakes etc a combination of machined aluminum and carbon I think would work very well together. fast production parts need to be drawn with flanges etc so ease of room to trim parts get the vaccuum bag etc. with a proper machined mold made from even MDF parts can be made easy. I used to have a lot of 911 cars and was keen on the intake plenums but thenwanted to start racing PCA and found the 944 was the key to race entry. All the parts shown made be me and girlfriend





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Old 09-23-2018, 04:38 AM
  #395  
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Originally Posted by vt951 View Post
Anyone have a throttle body recommendation? I think it would be good to have one with an integrated TPS which is compatible with at least some of these engine management systems: VEMS, Megasquirt, Electromotive, AEM, Bosch, Motec

I'm looking at this one, made as an upgrade for a 302 or 351 ford mustang or lightning. This one is 80 mm, but they are also available in 70 mm if 80 is too big for some reason. It has a TPS built in, and has a place to bolt on an IAC motor. https://www.summitracing.com/parts/bbk-1514
the bmw m50 TPS fits on the audi throttle body With minor work.
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Old 09-23-2018, 10:42 PM
  #396  
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Originally Posted by ealoken View Post


the bmw m50 TPS fits on the audi throttle body With minor work.
Sorry, which audi throttle body?
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Old 09-23-2018, 10:51 PM
  #397  
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Originally Posted by autosea View Post
I have been following this thread with interest. I have six different forms of 944 , am boat building in composite and have dabbled in parts for Porsche. With the advance in drawing we now have compared to my skills as an old timer with little computer skills this project may be something that I can help with. When it comes to oil pans, intakes etc a combination of machined aluminum and carbon I think would work very well together. fast production parts need to be drawn with flanges etc so ease of room to trim parts get the vaccuum bag etc. with a proper machined mold made from even MDF parts can be made easy. I used to have a lot of 911 cars and was keen on the intake plenums but thenwanted to start racing PCA and found the 944 was the key to race entry. All the parts shown made be me and girlfriend
Thanks for offering to help. Really nice looking work on the 911 manifolds. For the moment, I am pursuing a cast aluminum manifold design. Perhaps there will be a need for some other carbon fiber parts.
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Old 09-28-2018, 01:50 AM
  #398  
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I see that Iroz motorsport has been mentioned for sourcing parts such as motor mounts, however I can only find dead links for 07K parts. On their website there aren't any 07k parts either. I guess Iroz no longer does 07K parts? Or am I looking in the wrong place?
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Old 09-28-2018, 02:12 PM
  #399  
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Originally Posted by EastEnd944 View Post
I see that Iroz motorsport has been mentioned for sourcing parts such as motor mounts, however I can only find dead links for 07K parts. On their website there aren't any 07k parts either. I guess Iroz no longer does 07K parts? Or am I looking in the wrong place?
You're right. I emailed them:
"It seems like some of the 07K parts I’ve ordered have been removed from your website. Is Iroz not going to make these anymore?
- Oil Adapter (to attach DS engine mount)
- 1.8T PS Pump Bracket
- Billet valve cover"

Their response:
"We do not plan to continue production of these products anymore, the limited ones I have left in stock will be the remaining amount of these items. We are focusing and producing new products for the RS3, TTRS, and MQB Platform."

Not to worry, the oil adapter and PS pump bracket will be easy to design and make, so I'll do that. A billet valve cover is also offered by Integrated Engineering, so I probably won't bother making those.
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Old 09-29-2018, 10:21 PM
  #400  
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Here are some updates on the intake manifold design. I got some pointers from an expert on the trumpet and plenum shapes. The rest is just designed to fit up and avoid all the obstacles (mainly the brake booster and hood). The OE fuel rail will bolt on.





Last edited by vt951; 09-30-2018 at 12:43 AM.
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Old 09-30-2018, 12:39 AM
  #401  
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I still need to add some vacuum/boost ports to the manifold design. Not sure how many will be needed yet. Any opinions?
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Old 09-30-2018, 12:59 AM
  #402  
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a threaded bung between each runner (so 4 total) for a banjo would be clean.
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Old 09-30-2018, 11:55 AM
  #403  
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Originally Posted by V2Rocket View Post
a threaded bung between each runner (so 4 total) for a banjo would be clean.
I don't know, that might be pretty tight there with the fuel rail and injectors there. How about something like this, on the bottom? I could have the casting machined flat so people can drill their own ports to install banjo or NPT fittings.

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Old 09-30-2018, 05:57 PM
  #404  
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I just assume have it pre-drilled in whatever configuration seems best; no preference here.
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Old 10-02-2018, 11:59 AM
  #405  
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Looking into throttle body sizing, I think the stock VW TB will actually work just fine. It is ~65mm, which should be good for well beyond my goal of 500 hp, 7000 rpm, 25 psi. The calcs I found on this said around 680 CFM would be needed to achieve those numbers, which gives air speed of around 220 mph through the 65 mm throttle opening... so well below speed of sound and all the efficiency losses that happen there.

For comparison, I think the stock 951 TB is only around 55 mm (can someone measure and let me know?).

Last edited by vt951; 10-02-2018 at 01:36 PM.
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