RUFFLY MACHINED FLANGE

PORT MATCHED FLANGES

RADIUSED PORT INLETS



AND SOME MORE ASSEMBLY

 

AND A FEW MORE




ill have it finsihed up tommorow
what do u guys think???

 

It is nice to see someone trying to come up with parts from scratch. I have made a few intake manifolds and really get thrilled when I see the power gains from them.

A couple of observations, I don't know if you just wanted to increase plenum volume only or you also wanted to shorten the runners as well. The increase in plenum volume will help out with the top end and assuming the heads / cam combo were not the limiting factor you should see some hp and carry the torque longer, IF you kept the runner lengths the same as the original design. I am suggesting that you weld in a separator between the runners that are next to each other to help keep them from pulling air out of the runners.

And to jump ahead of your progress shown on the picts. You may want to add a generous fillet to the top side of the lid / wall where the runner openings are. This will help remove stagnate flow areas in the upper corners.

Cheers and I can't wait to see dyno charts!

 

What do you mean by "fillet"?

 

fillet is just a radius to remove the corner.

 

yes i shortened the runners about 4 inches,and just about trippled the size/voulume of the plenum.the motor this is going on is turbocharged,though with the right cam this manifold should work well on a na engine
anyways heres some more shots.alls thats left to do is weld in the bungs for the vacum/boost line fittings.2 in the rear for the brake boosted and the heater controls,and 3 on the driver side of the manifold for my wastegate, blow off valve,and my fmu

 

looks really impressive, the only thing that would be better is if you smoothed out all your welds. the welding is really impressive though, did you do that yourself?

 

yeah i welded it,i would like to polish off the welds but it will weaken the strenght of them,which would resukt in the welds breaking under high boost conditions,im still undecided if im going to polish the manifold or send it out and get it ceramic coated

 

ceramic coating it will hold in heat. I did that to my custom one and have thought about blasting it back off but haven't. It can look nice, though. Good job on the manifold. Did you mig weld it or tig it?

 

its tig welded,thnx man

 

i think that maybe beadblasting it might be a good ideayou could mask off some kind of a design on the top of it and then get it blasted with some fine grit and you could then polish the design. it would give the whole plenum a consistent texture, i'm not too sure what that would do to the strength of your welds though.

 

if anything id polish it first,then lay down a stencil and blast a design so the design had a satin/brushed type finish

 

yeah, either way would look pretty cool

 

nice welds man..

 

Nice Work!

 

thnx guys
since everyone seems to like the welds hers a few close ups,its kinda hard to see cause of the flash but u can still see them.not my best but far from my worst lmao

 

What kind of welder are you using there? Sure beat my aluminum welds, but I’m hoping to get a lot more practice this summer.

Kinda looks like a gift wrapped elephant if you know what I mean… and I think that might get you into trouble at high boost levels… Large flat surfaces see a lot of force under boost and will tend to flex and pop, which may lead to work hardening and cracking with aluminum. If you’re going to dress it up anyway, add some reinforcement to the flat sides, maybe some ribs or something.

 

i use a miller syncrowave 300,the things prolly older then me but its the best welding machine ive ever used.
yeah i thought about that after,and im going to reinforce the production manifolds,though most of them are going on n/a engines and it wouldnt be an issue anyway.

 

you're going to produce and sell these?

 

yeah ive goten a huge amount of interest from the v6 guys on this from this board and a few others,and with a few mods to it i can also make it fit a 4thgen 3.4 v6 car.
ive still got some dyno testing to do,but i should be able to start producing them in 2-3 weeks,i have an identical one on my car now,was the original one i made,but this on has some improvements to it

 

Thats cool! You got to post some more pics on the final product!Some one try this on a V8

 

will do.

if somone wanted to donate me a tpi base and runners im sure i could do something for the tpi cars(and give said person a discount on the new plenum)

 

i know it'd be difficult but i think it would be pretty cool if you could do custom runners along with the plenum

 

Heh, I thought I recognized a certain character to those welds… I have a sychrowave SD180 that I dabble with. The Miller square wave transformer boxes and older “big boxes of copper” have a very distinct feel and look compared to something like a dynasty (I bought mine from a guy upgrading to a dynasty and got to see them making very similar welds, tubes welded to flat sections as bolt standoffs for mounting LS1 coils) side by side. Something like the other “red” inverter boxes that have gotten popular lately have a completely different weld quality to them also.

I’m curious, what tungsten are you using for those welds?

 

i use a 2% thorated tungsten (red ones)

 

hey guys im putting this into production in 2-3 weeks so if any of u guys have v6 cars take a look in the v6 section,for the info on cost and options

 

man thats an awesome lookin setup for V6 guys. and judging by your welding, i can tell its a good quality part thats not gonna have air leaks in it.

PS: nice wallpaper you got in your house

 

pictures do not do this paint justice, 2 step paint silver metalic base,with translucent blue top coat.
of course i was in a hurry to putit on the car so i had only given the paint 20 mins to set up, so i marked it all up,so i pulled it again today to blast it and repaint it.this time ill let the paint dry a few days before i attempt to reinstall the manifold

 

i dunno, i think i liked they way it looked bare better

 

ima a newb...to pretty much everything. whats plenum?