Hi,
Just finished tack welding up my intake manifold and wanted to share my handy work with you all.

Next step is to position the throttle cable bracket, tack weld in a plate which will house all the sensors and vaccum lines, order some injectors, injector bosses and fuel rails and get them mounted and tack welded into position and then finally get it all fully welded.

 

Looks good, but why didn't you use a wrap around style or vertical style? You're going to get alot of heat of the headers/turbo being that close.

 

looks awsome. what size turbo is that?

 

Pics are a little deceiving, there is quite a bit of room between the intake and exhaust. I have already purchased some cool-it exhaust wrap for the exhaust manifold and a turbo bag for the turbo housing. I'll also separate the two manifolds with a shield made from stainless steel.

Reason for this intake design was the spool up is effectively quicker and will require less effort by the compressor - more efficient

 

It's a Bulleyes/Borg Warner S480 turbocharger

 

Sorry but that is a terrible design all around.

 

You base this on what evidence...
the above quote, hehehe....HELLO!! the system is pressurized, you can't draw from a plenum when it's pressurized - pressure = *pushing* not *sucking*, hope you can differentiate between the two...
You should stick to car detailing and washing cars or whatever they do over there at Gorilla Race (Carwash) Engineering!

 

^ The only real problem you may have is idling. With such short PP runners to the engine, you will loose a ton of air velocity in the low rpm's. Remember your engine will always be NA till it starts making positive pressure. You need that velocity to help stablized the air volume that will enter the engine at really low rpms to help with idling. Now the top end should be a monster.

 

Looks great, and for the 30-50 seconds that cars will run at a time I don't think cranking the idle up to 2000RPM will be to big of an issue.

 

+1

 

It's people/comments like yours above, that keep me in business to be honest.....uhh washing cars that is

If you for a second think that because you have a "pressure producing device" on your engine, you can build a "manifold" as shitEE as you have and everything will be hunkEEdory than think again kiddoh.

And i "base" my statment on FACTUAL evidence that's been known in the automotive/race engineering world for longer than you've been alive. So before you get upset because someone dosen't like your "manifold" you should probably no more about what the hell your doing/talking about.

But hey, I hope your heat soaked, no runner, *** plenum, bread box of a "manifold" works out for you chief! Good luck

-J

 

If that's the case, why not just run the turbo compressor housing directly into the rotor housings??? I mean you could just do that right....and maybe put a few injectors in the compressor outlet too

-J

 

^^+1 ... I usually don't like to admit with people but I do have to take his side on that one. Just because the system is pressurized doesn't mean that you can't make the intake a little bit more efficient. Personally i would of made the plenum a little bigger to just have that extra bit of air on tap. Also why didn't you make the inlet more centered to the intake openings as oppose to the slant that you have? The smoother and straigher the air can flow in the better the throttle response should be. If really in a pressurized system you don't have to "suck" in any air why do you have air horns in your plenum? I think it would of been easier and cheaper just weld a pipe on there ... no? Correct me if I'm wrong but aren't air horns designed to shape the way the air goes inside to increase the velocity of the air for a better throttle response? We're just trying to help out thats all. I think that all the intakes that I've seen done with a slant like that are off of cars that can't fit a centered inlet.

 

Once again you provided us with no evidence, no ***FACTUAL*** information. If Gorilla Race Engineering was a thriving business then you would have no time to grace us with your presence - no doubt u have plenty of time on your hands especially having posted 1261 times.
Use your time more wisely and read up on fluid dynamics, so you have the ability to back up your statements with actual evidence
I hope your customers (the ones you wash and detail there cars for) are satisfied with your service because you obviously have no clue...


-P

 

Plenum size becomes redundant when system becomes pressurized, no power is made reducing or increasing plenum size (at high engine speeds and under boost). The only advantage you'd get with a larger plenum is torque (when not in boost though)

No room

I used the velocity stacks because they were accessible. The velocity stacks would definitely benefit my application especially because I have such short runners. It would help pull in air when not on boost and help smooth out the flow of air when under boost

http://en.wikipedia.org/wiki/Velocity_stack

 

I found some pics of some unusual intake manifolds
Take a look






Renault F1 V6 turbo, 1.5L 1200hp!!

 

You're absolutely right bud..... Good luck with your build

-J

 

Out of curiosity how many injectors will you be using and what sizes?

 

Definately not the way I would have designed it, but it will work, just not as efficeintly as it could. Theres a billion ways to skin a cat. Everyone has some prefferances for whatever reasons be it for performance, bling factor, space contraints, or ease of producing. NICE fab work none the less. Hard to tell from the pics, but how do you intend to control boost? I see the exhaust mani already painted but no provisions for a wastegate/s.

~Mike..............

 

I got friends who run 220psi that would tell you otherwise. Plenum size and shape matter, whether boosted or not. I agree with RacerXtreme7 it will work and may even work well. There are a few things I like about it, and a few things I would change. It's to your benefit to run it and then show us all to be wrong

 

8 in total
2 along the runner between the silicon hose and plenum and 2 on top of the plenum angled into the velocity stacks
The engine will run on straight methanol and I plan to compete in only dyno competitions here in Australia

 

What do you mean?

I definiately would of done it differently if space was a available
I feel this was the best I could

The plan was to run a relief valve on the intake, still thinking about that or I might run a wastegate instead
The paint was used temporarily to prevent rust

 

220psi, on what application?
You might be right, I've never built several intake manifolds to compare. This was my first intake manifold.
If size was a factor as you say, at what point does size become irrelevent?
From the SAE articles I've read for boosted applications, hp was quite even at high engine speeds (be it 1.5Litre or 4Litre plenum size). Torque was greater at lower rpm's with the larger plenum

Would you kindly tell us the pro's and con's about this design, I'd greatly appreciate it!

 

The throttle location isn't that important when your talking about a boosted set-up. When the plenum is pressurized, air is being forced in. Ideally you want the throttle body exit to be a turbulent free as possible as it enter the runners. That's how you make it more efficient.

 

Those are nice. Since you designed yours for just top end, then you wont have any problems.