Intake Porting
 

I am in the process of smoothing out all the corners, ridges, bumps and casting imperfections in my FC's intake system. Air likes curvy shapes (look at a modern passenger jet) and flows with less effort around such objects, but the stock intake system has a bunch of ridges, blunt faces, and restrictions that can be removed to keep from getting in the way of the incoming airflow.

Here is my air flow meter / maf sensor:

http://home.att.net/~jeff.g.quinn/port44.jpg
http://home.att.net/~jeff.g.quinn/port45.jpg
http://home.att.net/~jeff.g.quinn/port46.jpg

The start of my throttle body:

http://home.att.net/~jeff.g.quinn/port47.jpg
http://home.att.net/~jeff.g.quinn/port48.jpg

The middle section of the intake manifold:

http://home.att.net/~jeff.g.quinn/port41.jpg
http://home.att.net/~jeff.g.quinn/port40.jpg

The lower intake manifold:

http://home.att.net/~jeff.g.quinn/port42.jpg
http://home.att.net/~jeff.g.quinn/port43.jpg

Off topic, but some cheap S5 wheels I just bought (gotta love Ebay). They weigh about the same as the base model phone dial 14's did with their tires on, only with 205's, so I am pretty happy.

http://home.att.net/~jeff.g.quinn/paint99.jpg

The dynamic chamber:

http://home.att.net/~jeff.g.quinn/port49.jpg
http://home.att.net/~jeff.g.quinn/port51.jpg
http://home.att.net/~jeff.g.quinn/port52.jpg

The black plastic elbow:

http://home.att.net/~jeff.g.quinn/port50.jpg

WOW thats some awesome work man.

You should post up some close-ups of them so we can see your skills with the grinder. :D

When is the engine going in the FC? Are you going ahead with those NEW seals from rotary aviation?

Santiago

I should have it all together in a couple weeks, using the real world seals. It's been fun doing all this but I am ready to drive this car now.

Looks like a lot of work.
Im gonna have my brother in law make me an intake elbow in stainless steel, that should take care of the restrictiveness in FC stock intake.

Kim

Tell me about it! You don't know how much I just want to ditch the entire stock intake manifold and make my own, but I don't have the time. There is a lot of smoothing that can be done. It will be interesting to see how this system performs in the real world on a real engine, at a real 1/4 mile track or dyno. I'm going to have to get a future S-AFC tuned on a dyno anyhow so I will get a nice graph of this thing's output numbers as a prize. :)

I like the throttle body. Never even thought about trying to port the AFM. Is there even anything to port in there?

I can't wait to see this thing finally put together. I just slapped mine together this week. It really sucks though because I just started college and I went away for it and can't bring my car. Brand new engine and can't even drive it.

By the way, did you ever get your hands on those s5 rotors?

Most of the restriction in the airflow meter is from the filter adapter. Mine came with the car and it was blocking about 15% of the opening! So I ground it off and rounded the corners (this was a long time ago before I tore it all apart) and it really improved the midrange and low end response. There was still a lot of improvement possible from that starting point, however; things like raised ridges inside the opening of the meter or non matching profiles of the filter adatper to the meter opening, etc. All I tried to do was pretend I was making an airplane fuselage or jet engine . . . thinking like the air and smoothing it all out.

I never got an S5 core and decided to get on with life and use what I have. I should have bid on this one that was semi-local to me. The auction ended at $251! That is about what just the rotors cost on the used market! :banghead:

gret job but u shuld have gottin better wheels

*chuckle*

My priorities are different than most peoples'. 80% go and 20% show for me.

Join the club.... lol i think im at about 90% go, and 10% show interms of money spending right now :D:D

Your not the only one.

Sorry to hear that you won't be using the s5 parts. All in all it was just a huge headache for me, just should have bought a core instead of the parts individually. Either way it should be good once I can get back to my house to get it started. The wait is just killing me.

Im in for 100% performance, thats what I bought this car for, but ofcourse it doesnt hurt to look good while racing on the track.

The ported throttle body; now I just need to plug a couple of warm up plate holes.

http://home.att.net/~jeff.g.quinn/port53.jpg
http://home.att.net/~jeff.g.quinn/port54.jpg

I swear, every thread you make should be archived. :)

does any one know were i could get the pics from the begining of this post? they don't show up any more, or my computer is messed up.

Pics no worky anymore :)

no pics for me either.....

yeah, all I'm seeing is red x's :(...I was just searching for some of your posts to lighten my day and make my brain work

hey 88IntegraLS do you have the pics anymore. I would really like to see them

BUMP I'd like to see the pics too

this thread is dead, and someone pissed off 88integrals so he's not posting any more of his wonderful writeups.

I'm not pissed, I just lost my house (garage), income, internet pic hosting service, and free time. I'm an engineering student now!! I still have the pics of all the stuff I did.

I just autocrossed the car that this porting was done on, and it is a little too fast for its street tires and my present skill level. The power band is very broad before the car gets heat soaked (after a couple of runs) but the power above 4000 rpm is intense. I can't keep the rear tires behind the car during any kind of turns while nailing the gas in first to blast down a straight. I spun the car doing this last weekend (on a track this time) and made some of the onlookers cheer.