tooter's manifold adventure...

[BEEF]

that beats the crap out of the original plastic manifold (not a fan).

did you get the throttle body plate done yet?

[tk-421]

That's a rockin' setup!
Nice job.

[tooter]

Originally Posted by BEEF

that beats the crap out of the original plastic manifold (not a fan).

Yeah, it gets lots of bling points even if it doesn't work. I'm doing this as much for that really cool Formula 1 look as much as for any of the other reasons.

did you get the throttle body plate done yet?

Yes, it's done. I pick it up on Monday, and will post pics when I get it home.

I took the prototype flange and drilled and filed and Dremeled all of the peripheral clearances into it so that the new measurement data can be taken off of the corrected part and fed into the CNC machine for the finished version.

[Billiam]

Not to be a party pooper...but haven't you basically voided your warranty on just about anything that would pop a CEL?

[Golddeenoh]

if it pops a CEL then he puts his OEM parts back on, resets the ecu but disconnecting the battery, and goes on. as far as warranty, it is amazing what can be done to car with out voiding it and in general you can get away with a lot of simple mods for intake and exhaust it just depends on if they can prove that any problem that arises is a direct result of the mods applied.

[tooter]

Originally Posted by Billiam

Not to be a party pooper...but haven't basically voided your warranty on just about anything that would pop a CEL?

I'm a fuk warranty kind of guy...

...and am happy to assume all of the responsibilities of owning a new vehicle. I don't buy used vehicles either... always new ones.

[Billiam]

Originally Posted by tooter

I'm a fuk warranty kind of guy...

I can respect that.

[malibuguy]

Looks flippin awesome on there!

[anomoly40]

Wait...that wasnt the final piece? Can i revise my numbers? Didnt know you were going to pull the old switcheroo... :)

[tooter]

Originally Posted by anomoly40

Wait...that wasnt the final piece? Can i revise my numbers? Didnt know you were going to pull the old switcheroo... :)

Sure.

You can change your guess any time right up until I do the dyno run.

It would have been the final piece, but the flange had some fitment issues that needed refining so I resolved them today and the CNC guys will make a corrected part next week.

[mazilla]

Looks great! Are you going to bling it up with a polished fuel rail?

[tooter]

I'm a linear one-step-at-a-time person, and only focus my attention on what needs to be done right now.

I'm still at #1.

1. Flange Fit.
2. Throttle Body Fit.
3. Weld.
4. Blast.
5. Clean.
6. Dyno.

[Billiam]

1 million HP.

[mazilla]

Originally Posted by tooter

I'm a linear one-step-at-a-time person, and only focus my attention on what needs to be done right now.

I'm still at #1.

1. Flange Fit.
2. Throttle Body Fit.
3. Weld.
4. Blast.
5. Clean.
6. Dyno.

I get that, but I'd still put fuel rail in there somewhere so I didn't have to take all that stuff apart, maybe 5.5.

[cali yaris]

5a. Drive
5b. Disconnect the battery to clear the CEL (after noting the error code)
5c. Repeat.

Just kidding, I am truly hoping those steps aren't included.

[CrankyOldMan]

Originally Posted by tooter

It would have been the final piece, but the flange had some fitment issues that needed refining so I resolved them today and the CNC guys will make a corrected part next week.

Was it the bolt hole alignment, or perimeter clearance?

[tooter]

Originally Posted by cali yaris

5a. Drive
5b. Disconnect the battery to clear the CEL (after noting the error code)
5c. Repeat.

Just kidding, I am truly hoping those steps aren't included.

I have no idea... this is all new to me.
You know far more about that than I do since you have years of experience with your manifolds and are a lot farther along in the process than I am. They certainly have to have been test run by now. Have any of your own short or longer runner manifolds triggered check engine lights? And if they did, how did you address them?

One decided advantage is that the throttle body and engine on either side of my manifold are in exactly the same bone stock condition as with the OEM manifold.

So with the manifold itself as the only change I don't anticipate any issues. With no alteration of the size or profile of the actual entry and exit ports, utilizing all of the stock gasketing to insure a leak free design, and designing all of the adaptations to be smoothly transitioned, I'm optimistic that it will be just fine.

The check engine light issue would be greatly complicated if there were other concurrent changes being made. It would be much more difficult to address. This is why I'm focused just on making this one mod and nothing else.

[tooter]

Originally Posted by CrankyOldMan

Was it the bolt hole alignment, or perimeter clearance?

It was perimeter clearances. The top of the flange needs to be milled down 1mm to clear the stock fuel rail supports. It's really close, as I was able to drop in the flange easily just by slightly loosening the fuel rail bolts. There is a cylindrical sensor close on the left side so I filed a semicircle to clear it. Also at the center of the fuel rail there's a part underneath it which also needed a semicircle filed to clear.

They were minor and corrected with a file. The goal is to make the flange simply drop in.

How are you doing on yours? I hope that sharing the details of the process will help to move your manifold along.