tooter's manifold adventure...

[malibuguy]

That tooter looks great! Your experimental one looks like a jelly fish :p

[jetblast]

Better start making some porting templates. I would be interested to see what the physical diameter gains are. Looks like a nice improvement.

[tooter]

Porting to the existing runner size increases the entrance diameter from 38mm to 40mm because the welds overhang a little more than 1mm all the way around. This nets a gain in the cross sectional area of just a little over 11%.

After all the overhanging welds have been removed, I'm going to smooth out and profile the entrances to more of a "bell" shape which should improve the flow even more.

[tooter]

Originally Posted by malibuguy

That tooter looks great! Your experimental one looks like a jelly fish :p

Sort of does. Maybe I should call it the "tooter squid"... although that name has negative connotations. It may end up earning the name squid after I get the dyno results!

[tooter]

Cut the rest of the plenum off so that I could get the Dremel into the runner ports better...



Also gound off all the overhanging welds, and stainless steel bead blasted everything. This evens out all the grinding marks and will make it much easier to see the shapes of the ports while I'm grinding the bell mouths.

Before grinding...



...and after.

[Bluevitz-rs]

You going to smooth out the weld too?

[tooter]

Yes. That's the next step. I'm going to form bell mouths for the runners, but I need to be careful not to take off too much weld because that's the only thing holding the runners onto the baseplate.

[Golddeenoh]

smooth it out then make it Phallic for Garm. for some reason that now makes sense...

[jetblast]

Too bad ya don't own a flow-bench so we could see the before and after results. That's gonna be huge difference. Nice job!!!!!

[tooter]

Sorry, no flowbench... but I am going to dyno the experimental manifold, so a few runs will show if there's actually any improvement. If not, I'll simply cut off the plenum and try something else as I also have another even more strange idea I'd like to try out if this one doesn't work.

Pure R & D is fun.

[4/20 NEVER FORGET]

I love following this thread. Keep up the good work!

[tooter]

Thanks, man...
This whole adventure has been no end of fun and it's not over yet.

Ideas are always connected to other ideas, so it's simply a matter of implementing one idea to see if it works... and if it does, choosing another idea to implement from the other ideas which are connected to the first idea.

I'm also fascinated with "microbusiness". A microbusiness has all of the qualities of a large corporation, except it operates on a very small scale. First you come up with an idea, then you design the concept, then manufacture a saleable product, then use the proceeds to buy the freedom to do the research and development to explore other ideas.

A microbusiness has one huge advantage over a large corporation. Just one person exercises complete control over the whole process from concept, to design, to finished product. So all that's necessary is for one person to have a clear vision of what they wish to accomplish, and to simply be motivated by their own curiousity to explore the possibilities.

I believe that everyone should enjoy the fun of becoming an enterpreneur by cultivating their own microbusiness... something in which they are genuinely interested, and which can be implemented on a small enough scale that they can do it "on the side".

[jetblast]

The American dream of being your own boss.

Look forward to the dyno runs. Would be interesting to see a turbo dyno run comparison also. Once I get this employment situation under control, I'm gonna have to catch you for one of those flanges to go with my intake.

[tooter]

Originally Posted by jetblast

The American dream of being your own boss.

Once you get a taste of piloting your own little boat... you never go back to pulling an oar down in the hull of someone else's ship.

Look forward to the dyno runs. Would be interesting to see a turbo dyno run comparison also. Once I get this employment situation under control, I'm gonna have to catch you for one of those flanges to go with my intake.

There's no rush as I always keep them in stock.
I think that the Corolla manifold would excel in a forced induction situation simply because it's so much less restrictive than the stock manifold.

[tooter]

Met with the CNC guys today and the 1ZZ throttle body base plate is in the works.

We came up with a simple practical design that will fulfill two purposes. The first purpose is of course the tooter e. t. manifold. And the second purpose is to make it possible to install a larger 55mm 1ZZ throttle body onto a Blitz supercharger.

Installation would involve cutting off the existing 1NZ 46mm flange with a hack saw, and welding on the 1ZZ 55mm throttle body base plate which will work for both the 46mm and 55mm throttle bodies. The smaller entrance to the SC would need to be flared out with a file or a Dremel to smoothly transition to the larger bore of the base plate.

The combination throttle body base plate/bellmouth will be 2 inches thick, with the top inch being the square 4 threaded stud base with the O ring gasket groove just like the original tooter adapter plate...



The bottom one inch will be a continuation of the 55mm diameter throat smoothly terminating at a rounded bellmouth profile similar to these...



...except that the outside diameter of the mouth will be exactly the same as the outside diameter of the intake. This combination base plate/bellmouth could be also easily be attached to any custom fabricated plenum if someone was building their own custom intake manifold from scratch.

I'm only having one extra made as I have no idea if there is any interest in this new product. It'll be $165 including shipping, so let me know now if anyone wants dibs on it.

[Viperoni]

Figured I'd drop this in here :)

http://www.racerxfabrication.com/pag...ge1/page1.html

[tooter]

Thanks for posting that, Viper. RacerX has some very clever ideas.

Notice the first manifold is the stock cast MR2 runners with their own custom plenum design attached to them And note the V8 Mustang throttle body base plate bore. It must be 80mm!



The straight runners are so long on the last manifold it's a cold air plenum because it's located in the trunk.



I've found a few others doing the same thing while searching the internet for manifold inspiration. Every other manufacturer I've seen starts with a basic one inch CNC baseplate as the foundation for their designs. That's the beauty of aluminium. It's cheap, light, and easy to machine and to weld.

[CrankyOldMan]

Originally Posted by tooter

So the ingredients to make this intake are:

Weapon R Dragon Short Ram polished aluminium intake tube, cut in half
BLOX 2.5" x 6" Velocity stack, mounting flange cut short
BLOX dry 6" matching dry element air filter
black 2.5" 90 degree coupling, ends trimmed short
black 2.25" straight coupling, trimmed short

These make a smooth flowing very low restriction intake.

I specifically chose the Weapon R tube because the MAF sensor mount is very close to the throttle body, and so could allow for severe cutting while still retaining its operational integrity.

Dragging out an old post from page 38-ish to ask a few questions.
- Could you use the stock MAF tube instead of chopping the Weapon R?
- How does the quality of the BLOX compare to other less expensive kit, e.g. the stuff at AutoZone/AutoValue/NAPA/etc?
- Does having the stock MAF on a 2.5" tube cause issues? I was told (on these forums) that the slower air velocity in a larger diameter tube would lead to wonky behavior from the ECU. I'm assuming you haven't had issues to this point, yes?