tooter's manifold adventure...

[tooter]

Originally Posted by BEEF

that's beautiful. excel can be your friend. that will show you the advantages and disadvantages to your intake manifold.

you have quite the project going here. now I am chompin at the bit for more.

I don't even have excel. That's just a copy of what Harry emailed to me. He was very competent, diligent, and thorough.

[tooter]

Finalized the flange today. And they'll be starting on the throttle body adaptor next week. I'll be getting some scans of the 3D rendering this evening and will post an image. This is the CNC machine...



And this is the material for the prototype...

[BEEF]

I may want to throw those number in excel myself (if you don't mind) that way you will see the positive and negative areas of your intake manifold once you get the second dyno. if he doesn't provide those differences I would be glad to throw it together. it would only take a few minutes.

after getting under my car, I can see where the 1.75" exhaust is really restrictive. you may want to do an exhaust thread (after you finish with this one).

how much are they charging you to run on the dyno? I want to run my car when it is all said and done with my mods. I was quoted $75 but not sure how many runs that is for. just trying to get something for comparison.

I wish I had a toy like that in my garage (the CNC machine)....I wish I had a garage. lol

[tooter]

Originally Posted by BEEF

I may want to throw those number in excel myself (if you don't mind) that way you will see the positive and negative areas of your intake manifold once you get the second dyno. if he doesn't provide those differences I would be glad to throw it together. it would only take a few minutes.

Please be my guest.

after getting under my car, I can see where the 1.75" exhaust is really restrictive. you may want to do an exhaust thread (after you finish with this one).

Sure will.
I just can't change anything until after the second dyno runs with the prototype manifold installed.

how much are they charging you to run on the dyno? I want to run my car when it is all said and done with my mods. I was quoted $75 but not sure how many runs that is for. just trying to get something for comparison.

It was $100 for the set of three runs... and I was happy to pay that for the service, because there is no other objective way to accurately quantify the change in performance with the prototype manifold.

I wish I had a toy like that in my garage (the CNC machine)....I wish I had a garage. lol

It's truly an amazing tool. I'm scheduled for machine time on Tuesday, the 17th.

[tooter]

Here's the 3D pics of the manifold adaptor flange...





They were done with Pro/Engineer 3D solid CAD modelling software.

If I can get time off work, I'll take a video of the machine making the part.

[CrankyOldMan]

Originally Posted by tooter

They were done with Pro/Engineer 3D solid CAD modelling software.

Noooooooo!! I learned Pro/E my freshman year at school and didn't like it very much. I've heard that it's great for sheetmetal work, but it's much clunkier and difficult to do solid modeling that competing products. That said, it does accomplish the task. I'm really stoked about seeing this project come together!

[tooter]

Originally Posted by CrankyOldMan

Noooooooo!! I learned Pro/E my freshman year at school and didn't like it very much. I've heard that it's great for sheetmetal work, but it's much clunkier and difficult to do solid modeling that competing products. That said, it does accomplish the task. I'm really stoked about seeing this project come together!

I know nothing about software. As long as it generates the right information so that the machine can make a part that fits.

In this pic you can see how the two outer ports slightly angle inward to meet the offset intake ports on the head. That's why I specified a 1 inch thick flange, so that the transition between the two would be reasonably smooth.



Here's the view fromt he other side where the transition is a little more noticeable. It's before adding the grooves for the stock O ring manifold gasket...

[BEEF]

is it really going to be an inch thick? I assume you are going to use different bolts to mount it.

[tooter]

Sure. They're readily available from the hardware store.

[BEEF]

just making sure our graphs line up. I can't wait for the second set. I am hoping to do a graph of the difference so you can see the drawbacks and advantages. I am hoping that there won't be much loss in the lower RPM range (2-3k) and a descen amount in the upper (4-5). I don't really care about 5-6k as most people don't hang out there much.

[tooter]

Originally Posted by BEEF

just making sure our graphs line up. I can't wait for the second set. I am hoping to do a graph of the difference so you can see the drawbacks and advantages. I am hoping that there won't be much loss in the lower RPM range (2-3k) and a descen amount in the upper (4-5). I don't really care about 5-6k as most people don't hang out there much.

Harry said that's likely going to happen. Definitely losses at the bottom with the possibility of gains at the top. How much is given up at the bottom is the question we'll find out.

We drive ours around hardly going over 3,000 rpm, so it's probably not going to help us for our uses. But since we already drive the car gently, the loss shouldn't be a problem. We'll just step on the gas a little more. I'm really curious on how much the gas mileage will decrease... although there's a chance that freeway mileage might increase.

There's only one thing we know for sure... at least it'll look really cool.

[BEEF]

I really like the look of the manifold you are using. here is an example of what I am talking about. of the 3 runs, here is the deviation between the worst and the best at each point (100 RPM step). I started it at 2500 since that was the first place I had all 3 data points. just to give an idea.



one trace for torque and one for horespower. seems you are within around 3 hp or ft/lbs even during the steep sloped part. actually a pretty tight grouping.

[tooter]

I see. That kind of graph could be especially useful to visually portray the difference between the before and after manifold runs.

[Golddeenoh]

Originally Posted by BEEF

at first when I saw this, all I could think of was

"wiggle wiggle wiggle"

http://www.youtube.com/watch?v=q33drZUXSzY

[BEEF]

but, but, but.......

IT'S DATAAA!!!!!!!!

[packetrace]

can't wait to see it and Garm's version :D!!!

[tooter]

Originally Posted by packetrace

can't wait to see it and Garm's version :D!!!

Same here... what happened to Garm's manifold.

On the 17th, I'll be holding in my hands all the parts to make it happen. After that the next step will be taking it to the welder, and then test fitting it on the engine. I'll be sure to post pics and videos of everything as it happens.

[cali yaris]

We got the final version to fit on our motor-on-a-stand, which it did. Now we're waiting on a pre-production version we can put on a test car and go dyno.