PDA

View Full Version : intake mods



shadow88
04-01-2006, 04:55 PM
This has been my winter project. I figured bigger's better, so .......enjoy! I goofed it up a bit, so start at the bottom. ok? cool.


[http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_comparerear.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/comparerear.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_comparepassenger.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/comparepassenger.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_comparedriver.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/comparedriver.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_comparefrontshot.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/comparefrontshot.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_newintakepassengercover.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/newintakepassengercover.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_newintakefrontandtop.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/newintakefrontandtop.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_cutup.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/cutup.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_smalleh.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/smalleh.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_neckdown.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/neckdown.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/th_ipeice.jpg (http://i77.photobucket.com/albums/j61/shadowt2/intake%20manifold/ipeice.jpg)

turbovanmanČ
04-01-2006, 05:06 PM
Looks good, :thumb: Wonder how it will perform? are you only changing the manifold or a bunch of stuff?

shadow88
04-01-2006, 07:56 PM
I plan to use a tbi style exhaust, 255 fuel pump, afpr, new clutch, and upgraded turbo. The intake has a few small leaks that have to be patched first. Then I'll add to vacuum ports.

After that I have to guess the power output at 19-22 psi to properly choose a turbo and clutch to match. any guesses?

It has a 58mm tb and that really is the smallest part of the intake track.
This morning I was testing cold start injectors to add the additional fuel.

On the upside, this cost countless hours and about $210. And It MUST be an improvement over the stock intake. (as seen in the 3rd pic from the bottom).

shadow88
04-06-2006, 10:29 PM
I really would like some inputs on the estimated power #'s

Before the manifold swaps it had around 230ishhp and around 280ish torque at the flywheel.

Any guesses would be nice to hear.

shadow88
05-07-2006, 09:51 PM
http://i77.photobucket.com/albums/j61/shadowt2/th_installed.jpg (http://i77.photobucket.com/albums/j61/shadowt2/installed.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/th_swingvavle.jpg (http://i77.photobucket.com/albums/j61/shadowt2/swingvavle.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/th_inthetrunnk.jpg (http://i77.photobucket.com/albums/j61/shadowt2/inthetrunnk.jpg)
http://i77.photobucket.com/albums/j61/shadowt2/th_bwahahafits.jpg (http://i77.photobucket.com/albums/j61/shadowt2/bwahahafits.jpg)


Damn, again, start from the bottom. I spaced out and forgot to bring a torque wrench, so it should run monday evening (for my neighbours) it only has about 2 1/2 feet of exhaut tubing on it. Next up is longer pipes for the turbo/intercooler, because it's set back a little more. enjoy!

cordes
05-07-2006, 10:12 PM
After that I have to guess the power output at 19-22 psi to properly choose a turbo and clutch to match. any guesses?





For that type of setup, I see no reason not to go with a hybrid turbo, and a 4 puck ceramic clutch. Call chris at TU, and he will be able to point you in the right direction. That thing should scoot. Although I would try to do some thing other than an extra inj. set up, as the rest of the parts are pretty nice. Why go with some thing that is less than ideal when putting that much time and energy into a project?

LynX853
05-08-2006, 05:26 PM
i think its pretty sweet and good to see new ideas popping up!

on another note to go with that shiney intake...

POLISH UP THAT VALVE COVER!!! haha good luck!

t3rse
05-09-2006, 07:11 PM
i thought about doing the exact same thing. ever think about using velocity stacks? looks good, now i will have to get mine going, feel left out now!

Dave
05-09-2006, 10:29 PM
That looks great! I'd like to see some flow bench comparisons actually.

About how long did that take you?

shadow88
05-11-2006, 06:54 PM
on tuesday night, it ran for the first time in months:cheer2: The fumes from the exhaust are too much to allow me to stay in the garage to bleed the cooling system. It seems the 10 degrees or so the oil return tube is on is sufficient, no smoke.:thumb:

crodes, when it's running well, it'll go to a dyno and THEN the proper turbo will be purchased. As for the 5th and possibly 6th injector set-up....I have a 3 bar controller from Dean Stillie and although it's great at the strip, it's kind of on or off for normal driving. This IS my daily driver.

lynx853, polish? you don't know me very well, I work on something for function over form, when it works right i stop. But I do have a SHELBY valve cover to go back on.

t3rse, pm me with any queston you may have about making your own. By veloticty stacks do you mean just longer runners? never seen velocity stacks on a boosted car.

Dave, I do not have access to a flow bench so, sorry, no numbers, but I'd venture a guess it's capable of flowing more air than either 1 or 2 piece manifold. It took 4 months of late nights at work after work. Sorry to sound like a jerk but i made it to flow on a car, not a bench.

Thanks for the inputs and keep 'em coming!

t3rse
05-11-2006, 09:19 PM
http://www.sdsefi.com/techinta.htm

3/4 down the page or a better picture of a different intake...

http://www.sdsefi.com/ej22-15.jpg
above image found at: http://www.sdsefi.com/air12.html

quote from above page: "Velocity stacks to go on the end of the runners were shown to improve airflow by 19% on the flow bench over straight tubes"

BadAssPerformance
05-11-2006, 09:50 PM
Nice work! :thumb:

The S is Silent
05-11-2006, 10:19 PM
i thought about doing the exact same thing. ever think about using velocity stacks? looks good, now i will have to get mine going, feel left out now!

How are you going to do your velocity stacks? Stephane posted this link in another thread: http://www.rossmachineracing.com/uni_intakeparts.html

edit: I can't get the link to load now, but I remember it being awesome.

LynX853
06-10-2006, 11:26 AM
The S is silent... that link dosnt work... just lettin ya know

The S is Silent
06-10-2006, 12:56 PM
http://www.rossmachineracing.com/intakeparts.html

It looks like they changed the name of it...or I just suck at posting. Either way...here's the real one.

LynX853
06-10-2006, 01:44 PM
that site is AMAZING! thanks!

shelbyplaya
06-11-2006, 02:34 AM
hows the car drive with the new intake? and up-dates?

turbovanmanČ
06-12-2006, 04:53 PM
http://www.rossmachineracing.com/intakeparts.html

It looks like they changed the name of it...or I just suck at posting. Either way...here's the real one.


WOW, I could easily drop a few grand there, :thumb:

shadow88
06-12-2006, 09:37 PM
Yeah, actually, I do have some updates.

This thing's a beast. :thumb: Turbo lag has seemed to increase about 150 rpm. I suppose that's due to less port veloticty. But when she comes alive this car gives a new definition of TORQUE STEER!!

I have the exhaust completed in 2 1/2" pipes with a cut-out that's capped right now. Still no leaks and it's briefly been above 25 psi.

It seems to produce just as much power at 16 psi than it used to at 21 psi. I'm waiting until the weekend to plumb in the cold starts and reposition the fuel lines (very close to the swing vavle).

I'm sorry to say- work keeps me busy enough to not have enough time for my shadow. But soon enough, it'll be ready for a trip to the dyno and eventually to the track. - sorry Ontario guys who may be reading this- it's just not ready for this saturday at st. thomas.

Thanks for showing intrest in my frankencar.:)

ShadowFromHell
02-03-2011, 03:29 AM
What did you use to weld the flange onto the TBI mani? How long have you been running it, and have you had any cracking problems? I like the intake, I want to build one and yours has made me think outside the box!

shadow88
02-07-2011, 06:35 PM
For welding the exhaust, I used a flux core wire MIG with careful pre and post heating. There are no cracks, there have been no repairs from the day it was made and still holding strong. Same welding procedure for the swingvalve. I was told the only way to do it was with a nigh nickel rod Arc welder, but I tried my way and it works just fine. The pre and post heat are very important. Also, make the flange with the studs before trying to weld it on.

ShadowFromHell
02-07-2011, 08:30 PM
Good info. I think I am going to try to build one, if it doesn't work I wont be out much. What did you use for the flange? Aftermarket mild steel or did you cut one out of a stock mani? Im going to build one for a mitsu turbo (20g) and a stock flange will not be easily obtainable for me. How many miles/runs do you have on it?

shadow88
02-07-2011, 09:55 PM
If I remember right, the flange was cut on a mill as partial payment for a side job using a stock manifold flange as a pattern enlarged slightly. It was mild steel and I think the thickness was 1/2"

As far as longevity, it's 4 full years of driving, some racing and plenty of tuning. I know it's been through many heat cycles and it has been hot enough to emit light on a few occasions. Because you asked, there's probably around 25,000 miles on it. Maybe50 passes at the drags. It has outlasted the intake manifold, but that's another story lol.

ShadowFromHell
02-07-2011, 10:34 PM
Thats good to hear! The fear of cracking has always made me nervous about building a TBI mani.

shadow88
02-08-2011, 07:03 PM
I see you know how to weld, so you'll be fine.
I made a few practice welds on warped and cracked manifolds I had in the shop at the time just to get the technique right before doing my tbi header.

turbovanmanČ
02-18-2011, 05:57 PM
I see you know how to weld, so you'll be fine.
I made a few practice welds on warped and cracked manifolds I had in the shop at the time just to get the technique right before doing my tbi header.

How did you heat it up? Torch or oven?

shadow88
02-18-2011, 06:19 PM
Oxy/ acc. torch. I only did a small section at a time. About 2 inches of heating, then weld, then back on the same area to re-heat and bring out impurities, then onto the next 2 inches. Practice brought me to that technique, maybe your results will differ.