tooter's manifold adventure...

[tooter]

I ran out of tooter adaptors (and manifolds) and ordered a couple more. This offered the opportunity to slightly tweak the design to remove the 2mm step around the top perimeter so that I don't need to round it off with a Dremel any more...

[CrankyOldMan]

Conical taper, eh? I'm planning on going to visit my S/C this afternoon so I can take some pics and rubbings. I figured the best way to get scale representation of the surfaces is to do the old graphite-on-paper transfer trick and then add measurements by hand.

[tooter]

Originally Posted by CrankyOldMan

Conical taper, eh? I'm planning on going to visit my S/C this afternoon so I can take some pics and rubbings. I figured the best way to get scale representation of the surfaces is to do the old graphite-on-paper transfer trick and then add measurements by hand.

Yes, the machined taper is so slight and even you can't see it...



...and naturally everything gets bead blasted.

[tooter]

Oh, oh... looks like tooter has gone off on another adventure...



This one was totally nasty. It took a whole can of engine degreaser just to get it looking like this. I hate working with dirty parts, so at least I can handle the manifold without getting black hands.







...and this one is pure R & D (Research and Development). I haven't yet decided exactly how to go about this because it's something totally outside the box. So I'll let you guys know when my idea actually takes shape.

[malibuguy]

according to one of the Yaris manuals that screen is for noise reduction. anybody running without it???

[tooter]

Not yet...

You know, I thought about that metal lattice and was searching online to see if anyone else had any negative effects from removal. All I could find was problems with a screen on older cars, but that was in front of the MAF sensor. Removing it messed with the idle and A/F ratio for some vehicles. I can't see how removing it would cause any problems, although I thought it might make for smoother less turbulent airflow across the backside of the butterfly when it's less than fully open. The air flow over the tipped in end of the butterfly is smoother because it's slanted in the right direction whereas the backside tips upward into the airflow.

I just played it safe and used standard readily available off the shelf stock Toyota O ring gaskets on both ends. The metal lattice can simply be snipped out if desired.

[CrankyOldMan]

MUAHAHAHAHAHAHAHA!

[JustDidIt]

Awesome! Can't wait 2 see what you come up with..

[tooter]

It's gonna be a real doozy...
I'm sourcing the raw materials.

[malibuguy]

i like your thinking

[tooter]

This whole project has been so much fun.
One idea always leads to another so I'm going to follow them off the beaten path just to find out where they lead. It's my favorite kind of experimental approach:

"Adapting things to an unintended purpose."

[CrankyOldMan]

Originally Posted by tooter

This whole project has been so much fun.
One idea always leads to another so I'm going to follow them off the beaten path just to find out where they lead. It's my favorite kind of experimental approach:

"Adapting things to an unintended purpose."

Aah yes, the old "under-utilized engineer" syndrome: if you don't give them problems to solve, they start making up their own.

I had also played with some ideas for a new plenum involving 6" aluminum tubing and some CNC'd flanges, but I seem to have lost a large amount of the files when I uninstalled AutoCAD. If you're going to be doing the CAD work yourself and you want some flow analysis, I have access to ANSYS at school and SolidWorks Flowxpres at work.

[tooter]

Originally Posted by CrankyOldMan

Aah yes, the old "under-utilized engineer" syndrome: if you don't give them problems to solve, they start making up their own.

I had also played with some ideas for a new plenum involving 6" aluminum tubing and some CNC'd flanges, but I seem to have lost a large amount of the files when I uninstalled AutoCAD. If you're going to be doing the CAD work yourself and you want some flow analysis, I have access to ANSYS at school and SolidWorks Flowxpres at work.

Thanks for the offer Cranky...
But I leave that to the CNC guys. We go over the design details and they render them into a 3D visual, and then into xyz coordinates that tell the milling heads exactly where to go. The really nice thing is that the design office and the machine are all in one location.

[malibuguy]

I thought about recreating the plenum when I go to do mine...just because the factory is so damn ugly. But I wonder if a larger volume could benift even more?

[tooter]

Originally Posted by malibuguy

I thought about recreating the plenum when I go to do mine...just because the factory is so damn ugly. But I wonder if a larger volume could benift even more?

I unolcked some secrets in that "ugly" plenum...



There's a "reverse velocity stack" which extends into the center of that really small plenum.

And I noticed something else... even though the picture doesn't show it, nothing is at right angles or parellel to the plane of the runner entrances. Everyhing is cocked at odd angles including that velocity stack.

Now this could likely be for noise reduction as that seems to be a major consideration in passenger vehicles, or it could be to break up resonant harmonic frequences so as to smooth out the peaks and valleys in the power band over a wide rpm range. There is almost no information on the web about these intake manifold issues, so I'm going to go off in a direction which I think will work.

Because that's what life's all about...

...finding out.

[JustDidIt]

Originally Posted by tooter

Because that's what life's all about...

...finding out.

[CrankyOldMan]

I managed to re-install inventor and get my project back. Here's a crude 3D pdf of a concept assembly. It's rather machine-intensive for the lower flange, so it would really need to be CNC'd, but the upper part could probably be done manually.

If you look at the bottom (four-barrel) end, you can see that the inserts are all a little different depth. This is to allow the entire existing plenum to be cut off and still retain the same relative tube length when mating to the 1NZ cylinder pitch.

[tooter]

I'm going with a different concept that retains the existing rounded square base...



...to save the most costly and complex task of machining the 4 runner entrances. I already have some 6 inch tubing left over from the velocity stack spacer, and might use that. Although the other end will be something different if I can get a hold of the right materials.