Bespoke Intake Manifold B202

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More jackassery going on.
Velocity stacks commercially available

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Should mate up with the 2 inch diameter tubing perfectly.

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First cut at a form. Two mirrored half shells.

[speedysaab]

Looking awesome Dennis

Have you thought about a design like these:
https://store.jenvey.co.uk/turbo-plenum ... aplc70-mac

Dis you order your bends from here? http://www.mandrelbends.com/mandrel-ben ... gauge.html

Are the "2.00" Aluminium, 3.00" Radius, 11 Gauge, 180 Degree Mandrel Bend AL-11-200-300-180" likely to fit?

Thanks
Rob

[squaab99t]

Looking awesome Dennis

Have you thought about a design like these:
https://store.jenvey.co.uk/turbo-plenum ... aplc70-mac

Dis you order your bends from here? http://www.mandrelbends.com/mandrel-ben ... gauge.html

Are the "2.00" Aluminium, 3.00" Radius, 11 Gauge, 180 Degree Mandrel Bend AL-11-200-300-180" likely to fit?

Thanks
Rob

Thanks Rob,
That is an interesting setup from jenvey. Interesting as the would enter 90* (roll) to the velocity stacks as I read the drawing.
That is the place I bought my U bends from. About 4 hours drive from where I live. In reality I would have just liked a 45* bends with legs, but the full U bend gives me options to the alignment without having the intake flange and the plenum with the same runner spacing.
I’ll investigate 3-D printing the plenum as a whole in Ultem vs cnc aluminum hogout in two halves and welding together. I could bond a flange to the inner lip of the ellipses and bolt the back plate with welded velocity stacks to it.
Got the velocity stacks yesterday. High on the bling factor.
I’ll mock it up in cad and see what it looks like.

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More time behind the monitor. Modeled the velocity stack and cut them into the backplate. The two halves of the plenum are not water tight. Slight gap at the mating seam. If I 3-D print whole it I don't want the printer freak that they are not connected.
A little splash of Raul Red.

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Raul Red is out, new hotness in. I angled the throttle body opening 15* to promote flow to cyl 4. Spaced the velocity stacks at the same spacing as the intake flange which shortened up the whole assy. Constructed the plenum surfaces differently, now it is watertight and printing and/or machining should not be a problem.

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Some paper doll spatial work

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Sunday morning powerpoint engineering. The plenum volume is visually larger. Need to do some measurements. Kinda worried about increased volume across the Throttle Body opening, and a sharp drop in boost pressure.

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Turning 3D into 2D to plot and back to 3D with foamcor and a sharp exacto. Old school, quick and cheap for spatial evaluation.

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Tacked up with hotmelt

[Geoff]

Nice work so far Dennis! It looks tight in the pictures but I'm sure that when you get the stock stuff out the new stuff will have some good space.

In the past I've thought about 3D printing intake manifolds as well. I did a quick search around the 'web' and came across some chat from some folks who had tried it on their FSAE cars and how they had a hard time with durability, especially during backfires. It was hard to tell if this was recent experience or maybe something from 10+ years ago so it was hard to tell if they were using modern processing or a cheap FDM with an open mesh cross-section... I've had good luck with SLS for durable engineering prototypes and I'd think that DMLS would work for a manifold - but I haven't priced it out (Ford did on Block's truck...). I've also been really impressed with the MJF samples I've seen in terms of durability and cost.

[Jordan]

That’s a lot of alphabet soup!

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I may fall back to CNC Al. Printing maybe sexy and lower effort, but I too am worried about durability and handling the load. 20psi boost is just that, 200 pounds spread across a 2x5” area. A lot to ask from stitched together plastic.

[Jordan]

Dennis, can you go into some of the theory/math behind the design? I just saw an interesting video on how Porsche designs their turbocharged intake manifolds. Their primary function is to cool the intake charge through expansion and not necessarily for pulse flow characteristics. I guess it is net positive for horsepower in their application.

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Dennis, can you go into some of the theory/math behind the design? I just saw an interesting video on how Porsche designs their turbocharged intake manifolds. Their primary function is to cool the intake charge through expansion and not necessarily for pulse flow characteristics. I guess it is net positive for horsepower in their application.

There is some truth to a rapid expansion in volume, and the drop in temperature of a compressed gas. The perfect gas law.
As for my design, I’m kinda doing it backwards in using what is commercially available and working from there.
Plan is to get all cylinders equal flow- cubic feet per minute (cfm). Clearer line of sight to cylinder 4 and decrease the cross section of the plenum at cylinder 1 to increase the velocity to match the cfm