tooter's manifold adventure...

[TOUGEghost]

Originally Posted by tooter

Nice wheels!

[cali yaris]

^ he puts them on everything.

[xnamerxx]

Originally Posted by Shinare

^^^ RE: "long tube header" - Please forgive this noob question, it really is a question and not a troll, but why does it matter the length of a pipe? Don't you want the exhaust to just get out via the back of your car rather than in the engine bay?

Its about exhaust scavenging. At a certain length and diameter, the exhaust pulse will create a sonic negative pressure wave at the valve creating a vacuum. That vacuum helps pull up on piston, clear out the cylinder, and suck fresh air into the cylinder. The exhaust itself still exits in the original location in most situations. On most otto cycle engines exhaust contributes to about 5-15% of the engines theoretical performance potential, on 2 stroke engines it can be as much as 40%.
In my case I picked up 7hp and 6 tq over a DC header with the long tube header I designed.

[tooter]

Originally Posted by TOUGEghost

Nice wheels!

Thanks,

They were the closest truck wheel match to the ones on our Yaris.

[CrankyOldMan]

Originally Posted by xnamerxx

In my case I picked up 7hp and 6 tq over a DC header with the long tube header I designed.

Is that design, by chance, available for the rest of us? I'm sure there's a thread, but I'm really lazy in the morning.

[malibuguy]

That header is georgeous. Do you have any pictures of inside the collector?

[tooter]

Sorry, no. But the runners are as clean and neat on the inside as it they are on the outside. And I agree, it's an excellent example of the exquisite beauty of flow design, and I bought it solely because of its visual appeal.



Note the similarity?

[xnamerxx]

Originally Posted by CrankyOldMan

Is that design, by chance, available for the rest of us? I'm sure there's a thread, but I'm really lazy in the morning.

Nope, spent a bit too much time with it to show off.

[tooter]

Who could forget the freaking awesome sound of your dyno runs, namer?

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

I thought of your project every time I saw these.




But like you said, they only adjust for attitude, but not for length.

Had you come up with any other ideas to resolve the issue of engine arc travel? You seemed to be so close to a functional product.

[xnamerxx]

I did, it ended up being a bit of a compromise but a flex joint placed in the right place took care of that problem. So far I have 6+ momths of testing on the car and no failures to speak of(knock on wood).

The main reason I couldn't put it into production because I was never able to find a shop that I could get to mandrel bend the tubes for a reasonable cost. The total cost with labor and mending would have been well into the $1000+ range, so it didn't seem viable as something I could sell.

With all that being said I still don't get tired of the torque it produces, it almost feels like a jeep motor now.

[tooter]

I totally understand. New one-off products are always expensive. Could your header have a bung to accept the stock 02 sensor? And does it end before the stock cat? I'm just curious how much it alters the stock exhaust configuration. Oh, and does it hit anywhere under accel or decel?

[xnamerxx]

No it doesn't hit anywhere.
I'm not sure how it affects the stock cat configuration because I have a custom midpipe, but If I'm guessing you'd need to remove one and move the other. As for the o2 sensors it accepts both in close to the stock location. I chose to do that rather than move the o2 sensors since I have no way of modifying the timing delay for the o2 signal, the downside is I only read half the cylinders.

[tooter]

Originally Posted by xnamerxx

No it doesn't hit anywhere.
I'm not sure how it affects the stock cat configuration because I have a custom midpipe, but If I'm guessing you'd need to remove one and move the other. As for the o2 sensors it accepts both in close to the stock location. I chose to do that rather than move the o2 sensors since I have no way of modifying the timing delay for the o2 signal, the downside is I only read half the cylinders.

Sounds like you worked out all the bugs and have a good product with the only obstacle being prohibitive material costs. Maybe in the future something will happen to change that.

[tooter]

Originally Posted by xnamerxx

I chose to do that rather than move the o2 sensors since I have no way of modifying the timing delay for the o2 signal, the downside is I only read half the cylinders.

I wouldn't be too concerned about that, namer.

I just noticed these Doug Thorley headers that are really popular with the Tacoma 4.0 guys only sample one third of the cylinders!

[tooter]

The tooter et is taking shape...





The hole is still a couple of millimeters smaller than the bellmouth so I'll Dremel it for a nice snug fit ready to weld.



This is going to be an effing strange manifold...

Greg

[Flipper_1938]

What does the boob look like on the inside with the flange fitted?

[tooter]

Originally Posted by Flipper_1938

What does the boob look like on the inside with the flange fitted?

It's really close, but bellmouth doesn't quite fit in all the way. I purposefully drilled the hole small as the hole saw does a considerable bit of wandering. This gives me the opportunity to precisely trim the hole for a good fit. I'll post a pic of the inside when I'm done with grinding the opening.

[tooter]

After a couple of hours grinding filing and sanding the bellmouth has a nice snug fit...









The runners remain in direct alignment with the axis of the throttle body bore...






This is the inside of the plenum, there is a complete lack of any flat reflective surfaces. I'll find out what happens then the pulses travel out the mouths of the runners and hit only curved surfaces.