tooter's manifold adventure...

[CrankyOldMan]

So many Freudian themes in this project! I was wondering where the actual seam would be on the bellmouth--for some reason I was thinking you would put it all the way up to the squared shoulders.

[cali yaris]

It looks from the picture, that because of the angle, the throttle body points more directly at two runners, which are slightly further away. See your second picture above. It would be interesting to see a flow test for to see how much each runner is getting.

[tooter]

Originally Posted by CrankyOldMan

So many Freudian themes in this project! I was wondering where the actual seam would be on the bellmouth--for some reason I was thinking you would put it all the way up to the squared shoulders.

That's right, Cranky. I had originally planned for it to drop all the way down to the square corners, but that makes the round part of the bellmouth drop below the contact surface of the hemisphere creating a gap. While the welder could easily fill that gap, I want to try to keep burn through to a minimum by retaining complete contact between the two surfaces so that the inside surface is not compromised.

It took a couple of hours of handwork to get the fit as precise as possible, and I'm totally satisfied with the results.





When I bead blast the whole assembly to normalize all of the surfaces, you'll hardly be able to see the seam even with no welding.

The raised square corners will end up working out nicely as the whole circle of the contact seam is easily accessible to be welded from the outside of the hemisphere. Exploring how to make the best of each detail in the design process is what makes this project no end of fun.

[tooter]

Originally Posted by cali yaris

It looks from the picture, that because of the angle, the throttle body points more directly at two runners, which are slightly further away. See your second picture above. It would be interesting to see a flow test for to see how much each runner is getting.

I know. The offset angled orientation of the throttle body axis in the original plenum was even more offset than the one I'm building. So I softened it slightly. If it wasn't an issue for Toyota, it isn't for me. I think it was done just to get the throttle body pointing slightly upwards to line up with the stock air filter box, so I did the same thing so as to line up with mine.





This is the original manifold throttle body axis orientation.



And this is the tooter et throttle body orientation.



This is why I don't believe that it was ever an issue. First because the flow is so direct, and second the runners are pulling from the plenum That's what I like most about this particular design. It completely eliminates the 90 degree "kink" runner to throttle body axis orientation found in all of the other typical plenum designs.

[jetblast]

Looking ever sooooo smooth!!! Nice!!

[Flipper_1938]

Is it done yet?

[cali yaris]

^ He is currently testing it on Alpha Centauri.

[Astroman]

Originally Posted by Flipper_1938

Is it done yet?

Hey that's the post I see the most on my thread, Something Big is Coming!

[tooter]

Originally Posted by Flipper_1938

Is it done yet?

Not yet.
Right now, the CNC machinist is making a base plate to connect the hemisphere to the intake runners. After that, I make the 3 tubing fittings, everything gets welded up and then I get to drive it.

[tooter]

The machine shop at Origin Designs made two more flanges. Their work is impeccable...



Also got a Corolla manifold to build into another tooter.

[jetblast]

Nothing like billet jewelry.

[tooter]

Here's the CNC machine making tooter intake manifold flanges two at a time...

http://www.youtube.com/watch?v=rh4Ho5tI8KA

[tooter]

Picked up the tooter et plenum to runner connecting plate today. It's far beyond what I had expected! The plate fits so precisely to the runner base, I couldn't pry it off so I'll just leave there to be welded on. the hemisphere sets on a ledge and centers itself.





Now I'll do one last on the car fitting to rotate the hemisphere and mark the best attitude of the throttle body to line up with the intake.







Next, the hemisphere will be drilled to accept some aluminum tubes for the three hose fittings. Then the whole assembly goes off to the welder!

[Astroman]

Looks great!

[Flipper_1938]

Originally Posted by tooter

Picked up the tooter et plenum to runner connecting plate today. It's far beyond what I had expected! The plate fits so precisely to the runner base, I couldn't pry it off so I'll just leave there to be welded on. the hemisphere sets on a ledge and centers itself.

Now I'll do one last on the car fitting to rotate the hemisphere and mark the best attitude of the throttle body to line up with the intake.




Next, the hemisphere will be drilled to accept some aluminum tubes for the three hose fittings. Then the whole assembly goes off to the welder!

Tooter's Titter!

Looks like quality design and manufacturing! I'm anxious to see how it works.

[tooter]

This is just a one-off "outside the box" experiment that will never see production because it's not cost effective. It's pure exploration just for the sake of curiosity.

[Flipper_1938]

Originally Posted by tooter

This is just a one-off "outside the box" experiment that will never see production because it's not cost effective. It's pure exploration just for the sake of curiosity.

If it makes a big number, I bet somebody will pay you to make another one.

After all, you now have a parts list (with math data).

[tooter]

Originally Posted by Flipper_1938

If it makes a big number, I bet somebody will pay you to make another one.

After all, you now have a parts list (with math data).

Although visually different, both plenums still hold the same 26 ounces of water. So the difference may not be that much. I'm curious as to whether a radically different plenum shape will make more gains. After a considerable amount of internet searching, as far as I know no one has ever tried anything as strange as this before. So we'll see what happens...