A few pics of my almost complete sheet metal intake manifold
07-16-06, 04:53 PM
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A few pics of my almost complete sheet metal intake manifold
I'm almost done with my intake manifold, so I figured I'd post a few pics.
This project orginally just started as a drawing in a Solidworks parametric modeling class, but I was taking advanced machining and TIG welding classes as well, so I decided to go ahead and build it. The flanges, velocity stacks, and injector bungs were machined by me in the schools machine shop.
The manifold is for my 13BT and is made from 6061 aluminum. I bought the tubing from Burnsstainless(******* expensive and they raped me hard on shipping) and the aluminum sheet and plate was sourced from Dave Parks, who got it for me for nearly free. The runners are sized for peak power at 6700-7000 RPM, and the plenum is ~120 in^3 if I remember correctly, I'll have to go back and check my notes. Velocity stacks have a 5 degree taper with .5-.75" bellmouth radius. I have about $300 in tubing, $130 in argon and welding supplies, and $40 in sheet/plate I still have to machine a couple small fuel rails, get the flanges decked, port match them to the block, and get it polished.
MUCH thanks to John Jackson and Kyle Hill of R&K Race Engines who let me use their badass shop and TIG welder for free.
This project orginally just started as a drawing in a Solidworks parametric modeling class, but I was taking advanced machining and TIG welding classes as well, so I decided to go ahead and build it. The flanges, velocity stacks, and injector bungs were machined by me in the schools machine shop.
The manifold is for my 13BT and is made from 6061 aluminum. I bought the tubing from Burnsstainless(******* expensive and they raped me hard on shipping) and the aluminum sheet and plate was sourced from Dave Parks, who got it for me for nearly free. The runners are sized for peak power at 6700-7000 RPM, and the plenum is ~120 in^3 if I remember correctly, I'll have to go back and check my notes. Velocity stacks have a 5 degree taper with .5-.75" bellmouth radius. I have about $300 in tubing, $130 in argon and welding supplies, and $40 in sheet/plate I still have to machine a couple small fuel rails, get the flanges decked, port match them to the block, and get it polished.
MUCH thanks to John Jackson and Kyle Hill of R&K Race Engines who let me use their badass shop and TIG welder for free.
07-16-06, 05:23 PM
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OBEY YOUR MAZDA
I'm impressed, sure as hell beats mine ...
http://www.wankelkim.net/rx7/fb/imag.../image125.html
http://www.wankelkim.net/rx7/fb/imag.../image125.html
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07-17-06, 06:43 AM
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07-17-06, 03:02 PM
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Very nice work!
Looks easier than all the work I did w/ the stock cast pieces to get them 1/2 decent and your is fully decent.
Only thing I see is I have a unqualified hunch a flowbench would show a D shape at the velocity stacks in the plenum right to larger radius bend would flow a hair more.
You will love the powerband if it works in the range you made it for. My '89 TII LIM to 3rd gen UIM seems to work in that range as my fuel bars peak at 6,500 rpm hold ~steady to 7,500rpm and slowly drop from there. Haven't dynoed mine yet.
What turbo/exhaust manifold is going on with it? I expect the exh mani will be as gorgeous!
Looks easier than all the work I did w/ the stock cast pieces to get them 1/2 decent and your is fully decent.
Only thing I see is I have a unqualified hunch a flowbench would show a D shape at the velocity stacks in the plenum right to larger radius bend would flow a hair more.
You will love the powerband if it works in the range you made it for. My '89 TII LIM to 3rd gen UIM seems to work in that range as my fuel bars peak at 6,500 rpm hold ~steady to 7,500rpm and slowly drop from there. Haven't dynoed mine yet.
What turbo/exhaust manifold is going on with it? I expect the exh mani will be as gorgeous!
07-18-06, 02:11 AM
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An additional brace will be added to the plenum after I get the flanges decked so I know exactly where it will sit. Vibration is one of the reasons I ran the tubing through the flanges and welded it from the back with a few structural welds on the front. I was going to go with an aftermarket TB, but I just didnt have the money so I'm just porting the **** out of my FD TB and using it.
07-19-06, 03:50 AM
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Looks pretty crafty! Can i ask you how you came up with the design? Like the piping diameter and velocity stack? Just curious if you had some sort of method to your madness or just went on looks? Hope that doesn't get taken the wrong way.....
07-19-06, 12:49 PM
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Originally Posted by silvr94r2
Looks pretty crafty! Can i ask you how you came up with the design? Like the piping diameter and velocity stack? Just curious if you had some sort of method to your madness or just went on looks? Hope that doesn't get taken the wrong way.....
My intentions during the design process was to create a manifold with runners symetric between the front and rear rotors(the stock LIM is FAR from symetric) while acheiving better flow through larger bend radiuses and higher air velocities. Piping diameter is very close to stock as I just sized it from my intake port runners. The velocity stacks were pretty much limited by the aluminum stock sizes I had on hand, but the overall design was taken from Maximum Boost.
07-19-06, 07:31 PM
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Originally Posted by DelSlow
Theres a little bit. My intentions during the design process was to create a manifold with runners symetric between the front and rear rotors(the stock LIM is FAR from symetric) while acheiving better flow through larger bend radiuses and higher air velocities. Piping diameter is very close to stock as I just sized it from my intake port runners. The velocity stacks were pretty much limited by the aluminum stock sizes I had on hand, but the overall design was taken from Maximum Boost.
My intentions during the design process was to create a manifold with runners symetric between the front and rear rotors(the stock LIM is FAR from symetric) while acheiving better flow through larger bend radiuses and higher air velocities. Piping diameter is very close to stock as I just sized it from my intake port runners. The velocity stacks were pretty much limited by the aluminum stock sizes I had on hand, but the overall design was taken from Maximum Boost.
07-19-06, 10:43 PM
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Wow, superhero like.
I bet you could walk into many fab shops with that in your hands and get hired on the spot.
Nobody drill me on this as I'm just thinking outloud, but wouldn't velocity and flow into the ports be higher if there was a straight section between the lower bends and the flange?
Have you decided on injector arrangement yet?
I bet you could walk into many fab shops with that in your hands and get hired on the spot.
Nobody drill me on this as I'm just thinking outloud, but wouldn't velocity and flow into the ports be higher if there was a straight section between the lower bends and the flange?
Have you decided on injector arrangement yet?
07-24-06, 10:38 PM
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Does anybody sell premade intake plenums? Ideally I'd like to buy something that tapers down near the back with a throttle body opening or place to add one on the other side.
Also, while I'm at it, what is the benefit of going with a large single blade throttle body -like an 85mm if the overall area of the valve is smaller than the stock 3 valve setup?
Also, while I'm at it, what is the benefit of going with a large single blade throttle body -like an 85mm if the overall area of the valve is smaller than the stock 3 valve setup?
07-25-06, 12:48 AM
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Wow. Very sweet. What performance gain do you think this setup will give you, it looks to me as if the runners are somewhat longer creating more torque, but that might be just the pics. and are you keeping the stock butterfly's or going with a bored out or 1 big round throttle body?
Keep up the good work
Keep up the good work
07-29-06, 12:45 PM
#23
Originally Posted by Jeff20B
Man you got lucky. Glad it worked out in the end. 
I'm amazed that is still being used. Nodisms
That manifold is awesome. You should make just a lower intake manifold to mate to a REW or BT upper. It would be ****.
Beautiful piece of work though
-Ben Martin
