Well the exhaust side can't have all the fun. Just north of 35,000 views.

9000 T5 head and Genuine Saab Nick T machined intake flange. Let the games begin.

What's the plan?

Built from “scratch”. Mandrel bends to take in account the 45* head. Tapered plenum, DBW throttle, velocity stacks, map/AIT combo bung, and maybe some direct port nitrous bungs. Hardcoat anodized and look dead sexy.
Using Plazmaman as my inspiration.



Jordan, might need cnc help with the plenum halves if you are interested?

Wow , Welding aluminum like that is not in my skillset! But yes, I'm happy to help if I can, cool project! Did you see the regulator/rail setup I made for the 8v? I was adapting those for 16v as well. Might also be a nice addition!

Yes, they have a welder with skills. I need to do a few more coupons before I get there.
I did see your 8v setup. Looks great and nice use of the AN fittings.
Thanks for the offer. I’ll work on a rough draft cad model. Not in a big hurry, as the exhaust manifold took over 2 years to complete.

Looks like it will be another great thread!

You have probably thought it out and researched it in great detail, but I have a few (sadly blurry) photos of similar manifolds from Trollspeed from the Saab Festival years ago if you'd like any inspiration...

Thanks Hutch, love to see what you got. I have one via the web, but always nice to see more.
As for more power off boost and on. It is all about ignition timing in my opinion. That is where the real power torque is made. Modern engine management makes that possible in the full rpm and load ranges.
This outa be another fun ride. Truth be told I have not done all the research that needs to be done; runner length, plenum volume and cfm flow. All in due time.

Not the greatest in the world, for some reason I have it stuck in my head that one was actually for 8V engines but that could be totally incorrect. I love the ITB one with the fuel injectors spraying right into the trumpet!

If I could make any sort of claim as to seeing common themes with some of these is that the actual runners are pretty short, at least compared with the OEM intake, and a larger plenum obviously.

Oh man, this thread needs to be x-rated so many beautiful pictures and work..

This thread is getting good. Hutch, I can see why the images are blurred, I'd be a bit shaky too if I saw those. It doesn't get X rating until some tooling is used.
Got my 11 gauge, 6061, mandrel U bends the other day. Made some tooling to form the oval cross section. Worked pretty slick, as the tubing seemed to be in 0 heat treat condition. no cracking and seemed to bend uniformly. Worked great on the straight section as the wall thickness is constant.
[attachment=0]24CAFBB6-4A6C-4632-AEA6-3D14FD00D861.jpeg[/attachment

Short test segment formed. Tool is sized properly to get the right inner dimensions.

Pretty awesome, Dennis!

What are you using for formulae, software, design guidance, etc. to plan out runner lengths, plenum volumes, etc?

Geoff wrote:Pretty awesome, Dennis!

What are you using for formulae, software, design guidance, etc. to plan out runner lengths, plenum volumes, etc?

Just getting into it. I’ll take some baseline measurements from the stock manifold and make some adjustments. In reality the stock manifold is not that bad based upon my afr measurements with the per cylinder readings. Part of the motivation is to make a matching manifold to the exhaust. Entered in a car-b-que today and the interests definitely gravitated towards the right side of the car. Needs balance.

Hi Dennis
Awesome new project !
What size tubing did you order and what tooling did you make to form the ovals?

Cheers
Rob

Thanks Rob, the tubing is 2 in OD 11 ga thick. When it is formed to fit the machined manifold flange it is 1.5 tall by 2.375 wide with full radius on the ends.
I’ve tried adding images/files to the forum and I’m like 1:20 so I added them to my instagram account. Search: squaab99t
I made my own tooling and some Swedish wrenches (aka hammers) get it formed. Also a panel beater shot bag helps. Without it, it is like an monkey F’in a football.